Multi-part nontoxic printed batteries

ABSTRACT

A battery-powered analyte sensing system includes a printed battery and an analyte sensor. The printed battery includes an anode composed of a non-toxic biocompatible metal, a first carbon-based current collector in electrical contact with the anode, a three-dimensional hierarchical mesoporous carbon-based cathode, a second carbon-based current collector, and an electrolyte layer disposed between the anode and the cathode, the electrolyte layer configured to activate the printed battery when the electrolyte is released into one or both the anode and the cathode. The analyte sensor includes a sensing material and a reactive chemistry additive in the sensing material.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation application of, and claimspriority to, U.S. patent application Ser. No. 16/740,381 entitled“Multi-Part Nontoxic Printed Batteries” and filed on Jan. 10, 2020,which claims priority to U.S. Patent Application No. 62/790,932 entitled“Systems for Multi-Part Nontoxic Printed Batteries” and filed on Jan.10, 2019. The present application also claims priority to U.S. PatentApplication No. 62/894,621 entitled “Systems for Multi-Part NontoxicPrinted Batteries” and filed on Aug. 30, 2019, to U.S. PatentApplication No. 62/926,225 entitled “3D Hierarchical MesoporousCarbon-Based Particles Integrated into a Continuous Electrode FilmLayer” and filed on Oct. 25, 2019, to U.S. Patent Application No.62/942,103 entitled “3D Hierarchical Mesoporous Carbon-Based ParticlesIntegrated into a Continuous Electrode Film Layer” and filed on Nov. 30,2019. The present application is also a Continuation-in-Part of U.S.patent application Ser. No. 16/706,542 entitled “Resonant Gas Sensor”(now U.S. Pat. No. 10,955,378) and filed on Dec. 6, 2019, which is aContinuation of U.S. patent application Ser. No. 16/239,423 entitled“Resonant Gas Sensor” (now U.S. Pat. No. 10,502,705) and filed on Jan.3, 2019, which claims priority to U.S. Provisional Patent ApplicationNo. 62/613,716 entitled “Resonant Gas Sensor” and filed on Jan. 4, 2018.All the above-referenced Patent Applications are hereby incorporated byreference in their respective entireties.

TECHNICAL FIELD

This disclosure relates generally to batteries and other electronic andmechanical components that are fabricated by three-dimensional (3D)printing techniques, and more specifically, to a point-of-use batterysystem that transitions to an activated state from a dormant state basedon a folding or peel-back action.

DESCRIPTION OF RELATED ART

Advances in the fields of electronics and telecommunications haveenabled consumers to user devices in many new applications. Portableelectronic devices and peripherals have already become commonplace, manyof which rely on battery-supplied power, and continue to increase inpopularity. Filling the electric power consumption demands,batteries-especially rechargeable (also referred to as “secondary”)batteries, have emerged as a universal solution, allowing for seeminglyindefinite portability and convenient continued device usage.

Nevertheless, challenges related to secondary battery performanceregarding lifespan and cyclability have attracted ongoing innovation inlithium-ion (Li-ion) batteries, which use an intercalated Li compound asa formative material at the positive electrode and graphite at thenegative electrode. Li-ion batteries, as opposed to other battery types,have been sought for usage in portable electronic devices due to theirhigh energy density, limited to no memory effect (describing howtraditional nickel-cadmium and nickel-metal hydride rechargeablebatteries lose their ability to store electrical charge over multiplecharge-discharge cycles involving partial discharge), and relatively lowself-discharge. Thus, Li-ion batteries offer many of the benefits foundin primary (non-rechargeable) lithium batteries, including high chargedensity that results in longer useful lifespans, without the concerns ofrapid discharge resulting in overheating, rupture or explosion that maybe encountered in Li batteries due to the highly reactive (andpotentially explosive and/or combustible) nature of Li metal.

To assist ongoing developments in Li ion battery specific capacity,cycle-ability, and power delivery, amorphous carbon has also beenconsidered (in conjunction with Li) as a formative material for Li ionbattery electrodes. Nevertheless, such electrodes continue to sufferfrom a relatively a low electrical conductivity (high charge transferresistance), which, in turn, results in a high polarization or internalpower loss. Conventional amorphous carbon-based anode materials also maytend to give rise to a high irreversible capacity, among creating otherpotential issues. Moreover, current Li-intercalated carbon-basedelectrode compositions or compounds typically include graphene,conductive carbon particles, and binder. In conventional techniques,carbon-based particles are all typically deposited, such as beingdropped into existing slurry cast electrodes including currentcollectors made from metal foil such as copper. Slurry typically isprepared to contain an organic binder or binder material referred to asNMP (N-methyl-2-pyrrolidone).

Studies have shown that fabricating battery electrodes by casting amixture of active materials, a nonconductive polymer binder, and aconductive additive onto a metal foil current collector can result inelectric or ionic bottlenecks, and poor electrical contacts due torandomly distributed conductive phases of carbon-based particles whenheld together using binders. Such problems are made worse incircumstances where high-capacity electrode materials are employed,where the high stress generated during electrochemical reactionsassociated with normal battery usage disrupts mechanical integrity ofsuch binder systems, ultimately resulting in decreased cycle life ofbatteries. As a result, a need exists for a carbon-based electrodematerial that addresses the challenges of Li ion batteries regardingusage of binders to impart structural integrity to secondary batteryelectrodes, and to have other highly desirable features, such as thoseconducive towards printable batteries suitable for integration withpackaging and shipment applications.

SUMMARY

This Summary is provided to introduce in a simplified form a selectionof concepts that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tolimit the scope of the claimed subject matter. Moreover, the systems,methods and devices of this disclosure each have several innovativeaspects, no single one of which is solely responsible for the desirableattributes disclosed herein.

One innovative aspect of the subject matter described in this disclosurecan be implemented as a: (1) initially inactive multi-part battery, (2)a point-of-use battery system, and (3) a multi-part battery to power ananalyte detector. Such batteries are configured into variousimplementations to be used in multiple environments and/or for multiplepurposes. An initially-inactive battery can include a first currentcollector having a cathode three-dimensionally (3D) printed thereon, thecathode comprising a first scaffolded mesoporous carbon-based material;a second current collector having an anode 3D printed thereon, thesecond current collector and the anode positioned substantially oppositeto the first current collector and cathode, the anode comprising asecond scaffolded mesoporous carbon-based material; and an electrolyteprovided in an initial dormant state, the electrolyte infiltrating ofpores of the first and second scaffolded carbon-based material to atleast partially enhance ionic charge storage therein and to complete anelectric circuit between the first and second current collectors, and totransform the initially-inactive battery to an active state uponplacement of the cathode substantially proximal to the anode and inabsence of directed thermal radiation.

In some implementations, when the electrolyte is in an active state, thebattery provides electric current to flow through an electric circuit.The first scaffolded mesoporous carbon-based material and the secondscaffolded mesoporous carbon-based material can each further include aplurality of electrically conductive three-dimensional (3D) aggregatesof graphene sheets. The aggregates can be sintered together to form anopen porous scaffold configured to provide an electrical conductionalong and across contact points of the graphene sheets. The open porousscaffold can include a 3D hierarchical structure with mesoscalestructuring in combination with fractal-like structuring, wherein thefractal-like structuring is formed based at least in part on a mass ornumber of primary particles, or based at least in part on a micro, meso,or macro characteristic of a cluster size. The first scaffoldedmesoporous carbon-based material and the second scaffolded mesoporouscarbon-based material can include a porous arrangement formed in theopen porous scaffold and configured to receive electrolyte dispersedtherein for ion transport through interconnected pores that define oneor more channels. In some cases, each channel of the one or morechannels includes: (1) a first portion that provides tunable ionconduits, (2) a second portion that facilitates rapid ion transport, and(3) a third portion that at least partially or temporarily confinesactive material.

Another innovative aspect of the subject matter described in thisdisclosure can be implemented as a point-of-use battery system thattransitions to an activated state from a dormant state based on afolding or peel-back action, the point-of-use battery system comprising:an anode composed of non-toxic biocompatible metal comprising any one ormore of Zn, Mg, or Al and configured to yield a cell voltage ofapproximately 1.5V-3V, a first printable carbon-based current collectorcomprising biocompatible multiple few layer graphene (FLG) sheets inelectrical contact with the anode and extending therefrom, a 3Dhierarchical mesoporous carbon-based cathode having an open porousstructure for gas diffusion with areas to catalyze active materialreduction comprising oxygen (O₂) and other gaseous species, the reducedoxygen creating water upon exposure to ambient air, the open porousstructure for active water management.

In some implementations, a polymer-based barrier film is applied overthe 3D hierarchical mesoporous carbon-based cathode to prevent oxygenand moisture from entering the open porous structure, the polymer-basedbarrier film being removable via the peel-back action to permit oxygento enter the open porous structure. The foregoing point-of-use batterysystem further includes a second printable carbon-based currentcollector comprising biocompatible multiple few layer graphene (FLG)sheets in electrical contact with the cathode and extending therefrom,an electrolyte comprising a non-toxic biocompatible aqueous solutionindependent of organic solvents, the electrolyte activating to conductions upon any one or more of the following situations: when an appliedpressure causes rupture of electrolyte containing polymeric microspheressuch that the rupture releases electrolyte that infiltrates the openporous structure and the anode; or when a hygroscopic compound havingsolid salts contained within the anode is activated such that thehygroscopic compound extracts moisture to solubilize the solid salts.

In some implementations, the foregoing point-of-use battery systemfurther includes an ion-impregnated cellulose support structure whereinany one or more of the anode or the 3D hierarchical mesoporouscarbon-based cathode is 3D printed on opposing sides thereof thatactivate upon exposure of the ion-impregnated cellulose supportstructure to O occurring upon the peel-back of the polymer-based barrierfilms. The point-of-use battery system can be configured such that theanode and the cathode each further include a 3D scaffolded mesoporouscarbon-based material. The scaffolded mesoporous carbon-based materialfurther can include a plurality of electrically conductivethree-dimensional (3D) aggregates of graphene sheets, the aggregatesforming an open porous scaffold that facilitates electrical conductionalong contact points of the graphene sheets.

In some implementations, the point-of-use battery is activated bydirectly or indirectly applying pressure to the anode or by directly orindirectly applying pressure to the cathode, or by directly orindirectly applying pressure to both the anode and the cathode. Thebattery system can be fabricated by any one or more of 3D printingand/or additive manufacturing techniques. In some situations, the anodeand and/or the cathode are 3D printed onto any one or more of a flexiblesubstrate, a semi-rigid substrate, or a rigid substrate, moreover insome situations, the substrate is formed by a portion of a shipping ormailing container. The shipping or mailing container may be formed ofcard stock, and/or cardboard, and/or paper, and/or polymer-coated paper.The flexible substrate, the semi-rigid substrate, or the rigid substratecan be produced as a label such as a shipping or mailing label.

Another innovative aspect of the subject matter described in thisdisclosure can be implemented as a multi-part battery system configuredto power a sensor having a sensing material with a chemistry additivefor detecting an analyte. Some of such implementations include an anode;a cathode; and an electrolyte, wherein activation of the multi-partbattery system to power the sensor is accomplished to release theelectrolyte between the anode and the cathode in directed absence ofthermal radiation. Once released, the electrolyte between the anode andthe cathode establishes ionic transport there-between. The sensingmaterial may include a particulate carbon. Any one or more of the anodeor the cathode are formed of electrically conductive three-dimensional(3D) aggregates of graphene sheets that form an open porous scaffold tofacilitate electrical conduction along contact points of the graphenesheets. The porous arrangement in the open porous scaffold is conduciveto receiving the electrolyte dispersed therein for ion transport throughinterconnected pores, thus providing power to an electrical circuit. Thesensor is an impedance sensor that is tuned to respond to presence of ananalyte such as nitroglycerine, sarin gas, mustard gas, or cyclone B.The sensor can trigger (such as by either directly or indirectlypowering) a beacon if the analyte is any one or more of nitroglycerine,sarin gas, mustard gas, or cyclone B to at least partially assist inlocation of a container equipped with the multi-part battery system.

In some implementations, one or more of the anode, the cathode, or theelectrolyte are substantially non-toxic to assist in biodegradabledisposal of the container at least partially. The foregoing multi-partbattery system further can include: (1) a flexible substrate; (2) aresonant gas sensor circuit comprising a transducer arranged on theflexible substrate; (3) a sensing material disposed on the flexiblesubstrate and electrically coupled to the transducer, wherein thesensing material includes carbon material in particulate form and areactive chemistry additive; and (4) an alternating current (AC) sourceconfigured to supply AC signals to a first terminal of the transducer,the AC signals comprising a range of frequencies, any one or more ofwhich stimulate the resonant gas sensor. Implementations further includea ground electrode electrically coupled to the transducer and non-groundterminal. The foregoing multi-part battery system can be configured suchthat the reactive chemistry additive reacts with the analyte to changeelectrical properties of the sensing material. The sensing material isinterrogated by the gas sensor circuit to detect the change inelectrical properties due to exposure of the sensing material to theanalyte. A carbon material in particulate form is used to enhancesensitivity of the gas sensor circuit when detecting the analyte.

Another innovative aspect of the subject matter described in thisdisclosure can be implemented as a point-of-use battery system thattransitions to an activated state from a dormant state based on afolding or peel-back action. Such a point-of-use battery systemincludes: (1) active electrode materials for both anode and cathodeconsisting of printable non-toxic biocompatible polymers, metaloxides/chlorides, metals, or carbon wherein the anode is composed ofmetal comprising any one or more of Zn, Mg, or Al; (2) a 3D hierarchicalmesoporous carbon-based cathode having an open porous structure for gasor liquid ionic diffusion and having areas to catalyze active materialreduction comprising oxygen (O₂) and water (H₂O) that is activelymanaged from ambient air or from amounts of MnO₂ or AgO that is loadedonto a carbon host structure; and (3) a carbon cellulose nanofibril filmthat serves as a non-toxic, biocompatible/bioresorbable electrolyte andthat serves as a separator between electrodes.

Details of one or more implementations of the subject matter describedin this disclosure are set forth in the accompanying drawings and thedescription below. Other features, aspects, and advantages will becomeapparent from the description, the drawings, and the claims. Note thatthe relative dimensions of the following figures may not be drawn toscale.

BRIEF DESCRIPTION OF THE DRAWINGS

Implementations of the subject matter disclosed herein are illustratedby way of example and are not intended to be limited by the figures ofthe accompanying drawings. Like numbers reference like elementsthroughout the drawings and specification. Note that the relativedimensions of the following figures may not be drawn to scale.

FIGS. 1A-1B show an exploded view of layers of a printed battery, suchlayers including elements of a cathode and anode portion, respectively.

FIGS. 1C1-1C2 show folding techniques related to activating aspects ofthe printed battery shown in FIGS. 1A-1B.

FIGS. 1D1-1D3 show example printed battery features.

FIG. 1E shows a flowchart related to a method for activating an exampleprinted battery.

FIG. 2 shows an example schematic for a traditional Li ion batteryincorporating the presently disclosed 3D self-assembled binder-lessmesoporous carbon-based particles.

FIGS. 3A-3F show illustrative schematic representations, at variousmagnification levels, and/or micrographs of a 3D self-assembledbinder-less 3D mesoporous carbon-based particle having tunableelectrical pathways and ionic conduits throughout the thickness thereof.

FIG. 3G shows a micrograph of an example enlarged section of the 3Dself-assembled binder-less mesoporous carbon-based particle shown in atleast FIGS. 1A-1E.

FIG. 3H shows an illustrative schematic representation of amulti-layered carbon-based scaffolded structure, each layer comprisingvarious concentrations of the 3D mesoporous carbon-based particles shownin FIGS. 1A-1F, deposited on an electrically conductive substrate.

FIG. 4A shows an illustrative schematic representation of amulti-layered carbon-based scaffolded structure, each layer comprisingvarious concentrations of any one or more of the 3D mesoporouscarbon-based particles shown herein, deposited on an electricallyconductive substrate, the multi-layered carbon-based scaffoldedstructure having lithium metal infused into nanoscale gaps therein.

FIG. 4B shows an illustrative schematic representation of a series ofplasma spray torches oriented in a substantially continuous sequenceabove a roll-to-roll (R2R) processing apparatus, where the plasma spraytorches are configured to grow the 3D mesoporous carbon-based particlesin an incremental layer-by-layer manner.

FIGS. 5A-5B show various photographs and/or micrographs related ofexample variants of the 3D mesoporous carbon-based particles shownherein.

FIGS. 5C1-5C3 show examples related to a printed battery featuringpressure-based electrolyte release capabilities.

FIGS. 5C4-5C5 shows an example of metal-air battery chemistry includingan air (cathode) electrode reaction and a metal (anode) electrodereaction.

FIG. 6A-6C shows views of a printed battery that can be activated at apoint-of-use.

FIGS. 7A-8A show self-aligning geometry that self-aligns even inpresence of lateral misregistration.

FIG. 8B shows an example listing of printed battery properties andadvantages.

FIG. 9 illustrates a configuration of an anode and cathodeinterdigitated therewith, both the anode and cathode being disposed on acomponent layer, which is disposed on a substrate layer.

FIG. 10 an exploded view of layers of an example printed battery, suchlayers including elements of a cathode and anode portion, respectively.

FIG. 11 an exploded view of layers of an example printed battery, suchlayers including elements of a cathode and anode portion, respectively.

FIGS. 12A-12B show an example where printed batteries are activated byan external source.

FIGS. 12C-18 show information, targets, properties, and relatedmaterials for printed batteries according to a variety of examples ofthe presently disclosed implementations.

FIGS. 19A and 19B show scanning electron microscope (SEM) images fromparticulate carbon containing graphene, in accordance with someimplementations.

FIGS. 20A and 20B show transmission electron microscope (TEM) imagesfrom particulate carbon containing graphene, in accordance with someimplementations.

FIG. 21 is a plan view schematic of an electrochemical gas sensor, inaccordance with some implementations.

FIG. 22 is a table that lists examples of possible redox mediators thatmay be used, in accordance with some implementations.

FIG. 23 shows an example of an electrochemical sensor where a firstelectrode and a second electrode are configured as interdigitatedfingers, in accordance with some implementations.

FIG. 24 shows an example of a chemical sensor in which high frequencyspectroscopy is used as the detection method, in accordance with someimplementations.

FIG. 25A shows a non-limiting example of a resonant gas sensor insideview and plan view, in accordance with some implementations.

FIG. 25B shows an example of a response from a resonant gas sensor inthe presence of an analyte of interest, in accordance with someimplementations.

FIGS. 25C-25D show non-limiting examples of resonant gas sensors insideview and plan view, in accordance with some implementations.

FIG. 25E shows a non-limiting example of a resonant gas sensor with asensing material containing particulate carbon, in accordance with someimplementations.

FIG. 25F shows a non-limiting example of a resonant gas sensor insideview and plan view, in accordance with some implementations.

FIGS. 26A-26C show a time evolution of example spectra produced when ananalyte is detected by a resonant gas sensor, in accordance with someimplementations.

FIG. 27 shows a non-limiting example of a chemiluminescent gas sensor,in accordance with some implementations.

FIG. 28 shows a non-limiting example of a sensor system in whichmultiple individual chemical sensors are used for detecting an analyte,in accordance with some implementations.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures. It is contemplated that elements disclosed may bebeneficially utilized on other elements without specific recitation. Thedrawings referred to here should not be understood as being drawn toscale unless specifically noted. Also, the drawings are oftensimplified, and details or components omitted for clarity ofpresentation and explanation. The drawings and discussion explainprinciples discussed below, where like designations denote likeelements.

DETAILED DESCRIPTION

Various aspects of the novel systems, apparatuses, and methods aredescribed more fully herein with reference to the accompanying drawings.The teachings disclosed can, however, be embodied in many differentforms and should not be construed as limited to any specific structureor function presented throughout this disclosure. Rather, these aspectsare provided so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart.

Based on the teachings herein one skilled in the art should appreciatethat the scope of the disclosure is intended to cover any aspect of thenovel systems, apparatuses, and methods disclosed herein, whetherimplemented independently of or combined with any other aspect of theinvention. For example, an apparatus can be implemented, or a method canbe practiced using any number of the aspects set forth herein. Inaddition, the scope of the invention is intended to cover such anapparatus or method which is practiced using other structure,functionality, or structure and functionality in addition to or otherthan the various aspects of the invention set forth herein. Any aspectdisclosed herein can be embodied by one or more elements of a claim.

Although some examples and aspects are described herein, many variationsand permutations of these examples fall within the scope of thedisclosure. Although some benefits and advantages of the preferredaspects are mentioned, the scope of the disclosure is not intended to belimited to benefits, uses, or objectives. Rather, aspects of thedisclosure are intended to be broadly applicable to a point-of-usebattery system that transitions to an activated state from a dormantstate based on a folding or peel-back action, the point-of-use batterysystem incorporating a 3D self-assembled multi-modal mesoporouscarbon-based particle composed of electrically conductivethree-dimensional (3D) aggregates of graphene sheets, some of which areillustrated in the figures and in the following description of thepreferred aspects. The detailed description and drawings are merelyillustrative of the disclosure rather than limiting, the scope of thedisclosure being defined by the appended claims and equivalents thereof.

Definitions Li-Ion Batteries

A Li-ion battery is a type of secondary (rechargeable) battery. Li-ionbattery technology has become very important in recent years as thesebatteries show great promise as power sources that can lead to anelectric vehicle (EV) revolution (referring to widespread implementationof EVs across numerous applications). The development of new materials(for Li-ion batteries) is the focus of research in the field ofmaterials science, as Li-ion batteries are considered to be the mostimpressive success story of modern electrochemistry. Li-ion batteriespower most modern portable devices and seem to have overcomepsychological barriers of the consuming public against the use of suchhigh energy density devices on a larger scale for more demandingapplications, such as EV.

Regarding operation, in Li-ion batteries, Li ions (Li+) migrate from thenegative electrode through an electrolyte to the positive electrodeduring discharge and return when charging. Li-ion batteriestraditionally use an intercalated Li compound as a formative material atthe positive electrode and graphite at the negative electrode. Thebatteries have a high energy density, no “memory—effect” (describing thesituation in which nickel-cadmium batteries gradually lose their maximumenergy capacity if they are repeatedly recharged after being onlypartially discharged) and low self-discharge. However, unlikeconventional battery chemistries, Li ion batteries can (due to thehighly reactive nature of elemental and ionic Li) present a safetyhazard. Under certain conditions, since Li ion batteries can contain aflammable electrolyte, if they are punctured, hit, otherwise damaged oreven incorrectly (excessively) charged, Li batteries can deteriorateunexpectedly, including through explosions and fires. Nevertheless, thehigh energy density of Li ion batteries permits for longer usablelifespans of several hours between charging cycles, and longer cyclelife, referring to the electric current delivery or output performanceof a given Li-ion battery over multiple repeat charge-discharge (partialor total charge depletion) cycles.

Li metal, due to its high theoretical specific capacity of 3,860 mAh/g,low density (0.59 g cm-3) and low negative electrochemical potential(−3.040 V compared to a standard hydrogen electrode), appears as anideal material for the negative electrode of secondary Li-ion batteries.However, unavoidable and uncontrollable dendrite growth, referring thegrowth of a branching tree-like structure within the battery itself,caused by Li precipitates can cause serious safety concerns related toshort-circuits, and limited Coulombic efficiency, referring to thecharge efficiency by which electrons are transferred in batteries,during deposition and stripping operations inherent in Li-ion batteries.Such challenges have previously impeded Li ion battery applications.

However, concerns related to safety of earlier-developed Li secondarybatteries led to the creation and refinement of newer generation Li-ionsecondary batteries. Such Li-ion batteries typically featurecarbonaceous materials used as an anode, such carbonaceous anodematerials including: (1) graphite; (2) amorphous carbon; and (3)graphitized carbon. The first type of the three carbonaceous materialspresented above includes naturally occurring graphite and syntheticgraphite (or artificial graphite, such as Highly Oriented PyrolyticGraphite, HOPG). Either form of graphite can be intercalated with Li.The resulting Graphite Intercalation Compound (GIC) may be expressed asLi_(x)C₆, where X is typically less than 1. To limit (minimize) the lossin energy density due to the replacement of Li metal with the GIC, X inLi_(x)C₆ must be maximized and the irreversible capacity loss (Q_(ir)),in the first charge of the battery must be minimized.

The maximum amount of Li that can be reversibly intercalated into theinterstices between graphene planes of a perfect graphite crystal isbelieved to occur in a graphite intercalation compound represented byLi_(x)C₆ (x=1), corresponding to a theoretical 372 mAh/g. However, sucha limited specific capacity (of the discussed theoretical 372 mAh/g)cannot satisfy the demanding requirements of the higher energy-densitypower needs of modern electronics and EVs.

Carbon-based anodes, such as (1) graphite intercalated with Li asdiscussed above, can demonstrate extended cycle lifespans due to thepresence of a surface-electrolyte interface layer (SEI), which resultsfrom the reaction between Li and surrounding electrolyte (or between Liand the anode surface/edge atoms or functional groups) during theinitial several charge-discharge cycles. Li ions consumed in thisreaction (referring to the formation of the SEI) may be derived fromsome of the Li ions originally intended for the charge transfer purpose(referring to the dissociation of elemental Li when intercalated withcarbon in a carbon-based structure, such as the anode, during Li ionmovement in electrolyte across a porous separator to the cathode asrelated to electron release and flow to power a load during Li ionbattery discharge cycles. As the SEI is formed, the Li ions become partof the inert SEI layer and become “irreversible”, in that they can nolonger be an active element (or ion) used for charge transfer. As aresult, it is desirable to minimize the amount of Li used for theformation of an effective SEI layer. In addition to SEI formation,Q_(ir), has been attributed to graphite exfoliation caused byelectrolyte/solvent co-intercalation and other side reactions.

Referring anode carbonaceous material introduced earlier, (2) amorphouscarbon, contains no (or very little) micro- or nano-crystallites.Amorphous carbon includes both so-called “soft carbon” and “hardcarbon”. Soft carbon refers to a carbon material that can be graphitizedat a temperature of about 2,500° C. or higher. In contrast, hard carbonrefers to a carbon material that cannot be graphitized at a temperaturehigher than 2,500° C.

However, in practice and industry, the so-called “amorphous carbons”commonly used as anode active materials may not be purely amorphous, butrather contain some minute amount of micro- or nano-crystallites, eachcrystallite being defined as a small number of graphene sheets (orientedas basal planes) that are stacked and bonded together by weak van derWaals forces. The number of graphene sheets can vary between one andseveral hundreds, giving rise to a c-directional dimension (thicknessL_(e)) of typically 0.34 nm to 100 nm. The length or width (L_(a)) ofthese crystallites is typically between tens of nanometers to microns.

Among this class of carbon materials, soft and hard carbons can beproduced by low-temperature pyrolysis (550-1,000° C.) and exhibit areversible specific capacity of 400-800 mAh/g in the 0-2.5 V range. Aso-called “house-of-cards” carbonaceous material has been produced withenhanced specific capacities approaching 700 mAh/g.

Research groups have obtained enhanced specific capacities of up to 700mAh/g by milling graphite, coke, or carbon fibers and have elucidatedthe origin of the additional specific capacity with the assumption thatin disordered carbon containing some dispersed graphene sheets (referredto as “house-of-cards” materials), Li ions are adsorbed on two sides ofa single graphene sheet. It has been also proposed that Li readily bondsto a proton-passivated carbon, resulting in a series of edge-oriented LiC H bonds. This provides an additional source of Li+ in some disorderedcarbons. Other research suggested the formation of Li metal monolayerson the outer graphene sheets of graphite nano-crystallites. Thediscussed amorphous carbons were prepared by pyrolyzing epoxy resins andmay be more correctly referred to as polymeric carbons. Polymericcarbon-based anode materials have also been studied.

Chemistry, performance, cost, and safety characteristics may vary acrossLi ion battery variants. Handheld electronics may use Li polymerbatteries (with a polymer gel as electrolyte) with Li cobalt oxide(LiCoO₂) as cathode material, which offers high energy density but maypresent safety risks, especially when damaged. Li iron phosphate(LiFePO₄), Li ion manganese oxide battery (LiMn₂O₄, Li₂MnO₃, or LMO),and Li nickel manganese cobalt oxide (LiNiMnCoO₂ or NMC) may offer lowerenergy density but provide longer useful lives and less likelihood offire or explosion. Such batteries are widely used for electric tools,medical equipment, and other roles. NMC in particular is oftenconsidered for automotive applications.

Electrical Conductance of Carbon-Based Materials

Advances in high conductance carbon materials such as carbon nanotubes(CNT), graphene, amorphous carbon, and/or crystalline graphite inelectronics allows for the printing of these materials onto many typesof surfaces without necessarily using printed circuit boards, and/orwithout the use of materials or compounds that have been identified asbeing toxic to humans. Usage of high conductance carbon as a feedstockmaterial and/or other material during any one or more of the additivemanufacturing processes described above may facilitate the fabricationof batteries (including Li ion batteries) with micro-lattice structuressuitable for enhanced functionality, electric power storage anddelivery, and optimal efficiency. Moreover, although many of the devicesdescribed may serve as power sources (batteries, capacitors), those ofskill in the art will appreciate that such 3D printing technologies maybe reconfigured using high conductance carbon materials such as carbonnanotubes (CNT), graphene, amorphous carbon, or crystalline graphite canform other electronic devices.

Printing technologies using high conductance carbon materials such ascarbon nanotubes (CNT), graphene, amorphous carbon, or crystallinegraphite may be implemented and/or otherwise incorporated in thefabrication of the following devices: antennas (tuned antennas), sensors(bio sensors), energy harvesters (photocells), and other electronicdevices.

Graphene

Graphene is an allotrope of carbon in the form of a single layer ofatoms in a two-dimensional hexagonal lattice in which one atom formseach vertex. It is the basic structural element of other allotropes,including graphite, charcoal, carbon nanotubes and fullerenes. It canalso be considered as an indefinitely large aromatic molecule, theultimate case of the family of flat polycyclic aromatic hydrocarbons.

Graphene has a special set of properties which set it apart from otherelements. In proportion to its thickness, it is about 100 times strongerthan the strongest steel. Yet its density is dramatically lower than anyother steel, with a surface (surface-related) mass of 0.763 mg persquare meter. It conducts heat and electricity very efficiently and istransparent. Graphene also shows a large and nonlinear diamagnetism,even greater than graphite and can be levitated by Nd—Fe—B magnets.Researchers have identified the bipolar transistor effect, ballistictransport of charges and large quantum oscillations in the material. Itsend-use application areas are widespread, finding unique implementationsin advanced materials and composites, as well as being used as aformative material to construct ornate scaffolds usable in Li ionbattery electrodes to enhance ion transport and electric currentconduction to yield specific capacity and power delivery figures nototherwise attainable by conventional battery technologies.

Chemical Functionalization of Graphene

Functionalization, as generally understood and as referred to herein,implies the process of adding new functions, features, capabilities, orproperties to a material or substance by altering the surface chemistryof the material. Functionalization is a fundamental technique usedthroughout chemistry, materials science, biological engineering, textileengineering, and nanotechnology and may be performed by attachingmolecules or nanoparticles to the surface of a material, with a chemicalbond or through adsorption, the adhesion of atoms, ions or moleculesfrom a gas, liquid or dissolved solid to a surface to create a film ofthe adsorbate on the surface of the adsorbent without forming a covalentor ionic bond thereto.

Functionalization and dispersion of graphene sheets may be of criticalimportance to their respective end-use applications. Chemicalfunctionalization of graphene enables the material to be processed bysolvent-assisted techniques, such as layer-by-layer assembly,spin-coating, and filtration and also prevents the agglomeration ofsingle layer graphene (SLG) during reduction and maintains the inherentproperties of graphene.

Currently, the functionalization of graphene may be performed bycovalent and noncovalent modification techniques. In both instances,surface modification of graphene oxide followed by reduction has beencarried out to obtain functionalized graphene. It has been found thatboth the covalent and noncovalent modification techniques are veryeffective in the preparation of processable graphene.

However, electrical conductivity of functionalized graphene has beenobserved to decrease significantly compared to pure graphene. Moreover,the surface area of the functionalized graphene prepared by covalent andnon-covalent techniques decrease significantly due to the destructivechemical oxidation of flake graphite followed by sonication,functionalization, and chemical reduction. To overcome these problems,studies have been reported on the preparation of functionalized graphenedirectly from graphite (one-step process). In all these cases, surfacemodification of graphene can prevent agglomeration and facilitates theformation of stable dispersions. Surface modified graphene can be usedfor the fabrication of polymer nanocomposites, Li ion batteryelectrodes, super-capacitor devices, drug delivery system, solar cells,memory devices, transistor device, biosensor, etc.

Graphite

Graphite, as commonly understood and as referred to herein, implies acrystalline form of elemental carbon with atoms arranged in a hexagonalstructure. Graphite occurs naturally in this form and is the most stableform of carbon under standard (atmospheric) conditions. Otherwise, underhigh pressures and temperatures, graphite converts to diamond. Graphiteis used in pencils and lubricants. Its high conductivity makes it usefulin electronic products such as electrodes, batteries, and solar panels.

Roll-to-Roll (R2R) Processing

R2R processing refers to the process of creating electronic devices on aroll of flexible plastic or metal foil. R2R processing may also refer toany process of applying coatings, printing, or performing otherprocesses starting with a roll of a flexible material and re-reelingafter the process to create an output roll. These processes, and otherssuch as sheeting, may be grouped together under the general term“converting”. When the rolls of material have been coated, laminated orprinted they can be subsequently cut and/or slit to their finished sizeon a slitter rewinder.

R2R processing of large-area electronic devices may reduce manufacturingcost. Other applications could arise which take advantage of theflexible nature of the substrates, such as electronics embedded intoclothing, 3D-printed Li ion batteries, large-area flexible displays, androll-up portable displays.

3D Printing—Generally

3D printing or Additive Manufacturing has found applications in variousmanufacturing, medical, industry and sociocultural sectors, which inturn have generated enough interest to further facilitate research anddevelopment. Also, 3D printing has been used in humanitarianapplications to produce a range of medical items, including prosthetics,spares, and repairs.

Earlier additive manufacturing applications concentrated on the toolroomend of the manufacturing spectrum, where, rapid prototyping was one ofthe earliest additive variants, and its mission was to reduce the leadtime and cost of developing prototypes of new parts and devices, whichwas earlier only done with subtractive toolroom methods such as CNCmilling, turning, and precision grinding. More recently, additivemanufacturing has entered production to a much greater extent.

Additive manufacturing techniques are adaptable and may be configuredfor an innumerable amount of end-use applications, including, by way ofexample, but not limitation thereto, food, such as by squeezing outfood, layer by layer, into three-dimensional objects. A large variety offoods may be appropriate candidates, such as chocolate and candy, andflat foods such as crackers, pasta, and pizza. Moreover, sourcesindicate that NASA is looking into the technology in order to create 3Dprinted food to limit food waste and to make food that are designed tofit an astronaut's dietary needs.

Moreover, 3D printing has also entered clothing, with fashion designersexperimenting with 3D—printed shoes and dresses. In commercialproduction Nike® is using 3D printing to prototype and manufacture the2012 Vapor Laser Talon football shoe for players of American football,and New Balance is 3D manufacturing custom-fit shoes for athletes. 3Dprinting has even progressed to a level where companies are printingconsumer-grade eyewear with on-demand custom fit and styling (althoughthey cannot print the lenses). On-demand customization of glasses ispossible with rapid prototyping.

3D Printing—Advanced Batteries

Applications of 3D printing related manufacturing techniques also extendto the manufacture of porous electrodes for lithium-ion batteries, whichwere restricted earlier due to limitations in the design of 3D printedelectrodes to just a few possible architectures. Until recently, theinternal geometry that produced the best porous electrodes throughadditive manufacturing required an interdigitated configuration wheremetal prongs are interlocked, such as like the fingers or “digits” oftwo clasped hands, with the lithium shuttling between the two sides.

Lithium-ion battery capacity may be significantly improved upon, at amicroscale level, if such batteries are produced with electrodes thathave pores and channels. And, although previously often used, aninterdigitated geometry allows for lithium to transport through thebattery efficiently during charging and discharging, but may not alwaysbe optimal depending on intended end-uses, etc.

Accordingly, researchers have developed a new methods of 3D printingbattery electrodes that creates 3D micro-lattice structures withcontrolled porosity, where 3D printing of such micro-lattice structureshas shown substantial improvement in the capacity and charge-dischargerates for lithium-ion batteries.

For lithium-ion batteries, electrodes with porous architectures can leadto higher charge capacities since such architectures or configurationsallow lithium to penetrate through the electrode volume leading to veryhigh electrode utilization, and thus higher energy storage capacity.Compared to conventional batteries, where 30-50% of the total electrodevolume is unutilized, battery electrodes manufactured by 3D printingcreate a micro-lattice electrode architecture that allows for theefficient transport of lithium through the entire electrode, which alsoincreases battery charging rates.

Developments in additive manufacturing methods likewise translate intocorresponding advances in capabilities regarding the printing of complexgeometries for 3D battery architectures, as well as important stepstoward geometrically optimizing 3D configurations for electrochemicalenergy storage, access, and delivery to devices.

Specific 3D-printed micro-lattice structures used as electrodes inlithium-ion batteries have been shown to improve battery performance inseveral ways, including, but not limited to: a fourfold increase inspecific capacity and a twofold increase in areal capacity when comparedto a solid block electrode, such as may be related to surface area tovolume ratios of such 3D printed micro-lattice structures. Further, 3Dprinted electrodes have been shown to retain their complex 3D latticestructures after many, such as forty, electrochemical cycles thusdemonstrating their mechanical robustness and ongoing reliability. Thus,such 3D printed batteries with specific microstructures can haverelatively high electrical charge storage capacity for the same weightor alternately, for the same capacity, a greatly reduced weight, such asby offering optimal surface area to volume ratios and configurations,which may be an important attribute for certain applications requiringenumerated parameters, such as transportation and medical deviceapplications, including implantable devices beneath the skin.

Until recently, 3D printed battery efforts were limited toextrusion-based printing, such as referring to a process used to createobjects of a fixed cross-sectional profile where material is pushedthrough a die of the desired cross-section. In applications to printcomplex micro-lattice structures, a wire of material may be extrudedfrom a nozzle to create continuous structures. Also, interdigitatedstructures are possible using this method as is the 3D printing ofbattery electrodes by rapidly assembling individual droplets one-by-oneinto 3D structures such that resulting structures have complexgeometries that would be otherwise impossible to fabricate using typicalor traditional extrusion methods.

Moreover, since droplets of material used for 3D printing are separatedfrom each other, the creation of complex geometries is possible, asopposed to traditional extrusion printing, which requires a singlestream of material.

The ability to create sophisticated and intricate 3D structures by 3Dprinting may be of particular importance in the fields of consumerelectronics, the medical devices industry, as well as aerospaceapplications. Related research may also integrate well with biomedicalelectronic devices, where miniaturized batteries are often required.Non-biological electronic micro-devices may also benefit fromdevelopments in 3D printing of battery microstructures. On a largerscale, electronic devices, small drones, and aerospace applicationsthemselves may also benefit from and use 3D printing technology as well,due to the low weight and high capacity of the batteries printed usingthis method.

Oxidation-Reduction (Redox) Reactions

Redox are a type of chemical reaction in which the oxidation states ofatoms are changed. Redox reactions are characterized by the transfer ofelectrons between chemical species, most often with one species, such asthe reducing agent, undergoing oxidation, losing electrons, whileanother species, the oxidizing agent, undergoes reduction, gainselectrons. The chemical species from which the electron is stripped issaid to have been oxidized, while the chemical species to which theelectron is added is said to have been reduced.

Intercalation

As commonly understood and as referred to herein, in chemistry,intercalation is the reversible inclusion or insertion of a molecule (orion) into materials with layered structures. Examples are found ingraphite, graphene, and transition metal dichalcogenides.

Li Intercalation into Bi- or Multi-Layer Graphene

Electrical storage capacity of graphene and the Li-storage process ingraphite currently present challenges requiring further development inthe field of Li ion batteries. Efforts have therefore been undertaken tofurther develop three-dimensional bi-layer graphene foam with fewdefects and a predominant Bernal stacking configuration, a type ofbilayer graphene where half of the atoms lie directly over the center ofa hexagon in the lower graphene sheet, and half of the atoms lie over anatom, and to investigate its Li-storage capacity, process, kinetics, andresistances. Li atoms may be stored only in the graphene interlayer.Further, various physiochemical characterizations of the staged Libilayer graphene products further reveal the regular Li-intercalationphenomena and illustrate this Li storage pattern of two-dimensions.

Electrochemical Capacitors (ECs)

Electrochemical capacitors (ECs), also referred to as “ultracapacitors”and/or “supercapacitors”, are considered for uses in hybrid or full EVs.ECs can supplement (or in certain uses replace) traditional batteries,including high-performance Li ion batteries, used in an EVs to provideshort bursts of power (forward propulsion) often needed for rapidacceleration. Traditional batteries may still be used provide uniformpower for cruising at normal highway speeds, but supercapacitors (withtheir ability to release energy much more quickly than batteries) mayactivate and supplement battery-provided power at times when the carneeds to accelerate, such as for merging, passing, emergency manoeuvres,and hill climbing.

ECs must also store sufficient energy to provide an acceptable drivingrange, such as from 220-325 miles or more. And to be cost- andweight-effective compared to additional battery capacity, ECs mustcombine adequate specific energy and specific power with long cycle lifeand meet cost targets as well. Specifically, ECs for application in EVsmust store about 400 Wh of energy, be able to deliver about 40 kW ofpower for about 10 seconds and provide high cycle-life (>100,000cycles).

The high volumetric capacitance density of an EC (10 to 100 timesgreater than conventional capacitors) derives from using porouselectrodes, which may incorporate, feature, and/or be constructed fromscaffolded graphene-based materials, to create a large effective “platearea” and from storing energy in the diffuse double layer. This doublelayer, created naturally at a solid-electrolyte interface when voltageis imposed, has a thickness of only about 1-2 nm, therefore forming anextremely small effective “plate separation.” In some ECs, stored energyis further augmented by pseudo-capacitance effects, occurring again atthe solid-electrolyte interface due to electrochemical phenomena such asthe redox charge transfer. The double layer capacitor is based on a highsurface area electrode material, such as activated carbon, immersed inan electrolyte. A polarized double layer is formed atelectrode-electrolyte interfaces providing high capacitance.

OVERVIEW Introduction

Advances in modern carbon-based materials(graphene) have enhancedapplications using such materials, such as in secondary batteries.Electrochemical Li intercalation or de-intercalation properties ofcarbon and carbon-based materials depend significantly on theirrespective morphology, crystallinity, orientation of crystallites, anddefects as well. Further, the electric storage capacity of a Li-ionbattery can be enhanced by the selection and integration of desirablenano-structured carbon materials such as carbon in certain allotropessuch as graphite and graphene, or nano-sized graphite, nanofibers,isolated single walled carbon nanotubes, nano-balls, and nano-sizedamorphous carbon, having small carbon nanostructures in which nodimension is greater than about 2 μm.

For example, known methods for fabricating carbon and Li-ion electrodesfor rechargeable Li cells include steps for forming a carbon electrodecomposed of graphitic carbon particles adhered by an ethylene propylenediene monomer binder used to achieve a carbon electrode capable ofsubsequent intercalation by Li-ions. The carbon electrode is reactedwith Li-ions to incorporate Li-ions into graphitic carbon particles ofthe electrode. An electrical current is repeatedly applied to the carbonelectrode to initially cause a surface reaction between the Li-ions andto the carbon and subsequently cause intercalation of the Li-ions intocrystalline layers of the graphitic carbon particles. With repeatedapplication of the electrical current, intercalation is achieved to neara theoretical maximum.

Other exfoliated graphite-based hybrid material compositions relate to:(a) micron- or nanometer-scaled particles or coating which are capableof absorbing and desorbing alkali or alkaline metal ions (particularly,Li ions); and (b) exfoliated graphite flakes that are interconnected toform a porous, conductive graphite network comprising pores. Theparticles or coating resides in a pore of the network or is attached toa flake of the network. The exfoliated graphite amount is in the rangeof 5% to 90% by weight and the number of particles or amount of coatingis in the range of 95% to 10% by weight.

Also, high-capacity silicon-based anode active materials have been shownto be effective in combination with high-capacity Li rich cathode activematerials. Supplemental Li can improve the cycling performance andreduce irreversible capacity loss for some silicon based activematerials. Silicon based active materials can be formed in compositeswith electrically conductive coatings, such as pyrolytic carbon coatingsor metal coatings, and composites can also be formed with otherelectrically conductive carbon components, such as carbon nano fibersand carbon nanoparticles.

And, known rechargeable batteries of an alkali metal having an organicelectrolyte experiences little capacity loss upon intercalation of thecarbonaceous electrode with the alkali metal. The carbonaceous electrodemay include a multi-phase composition including both highly graphitizedand less graphitized phases or may include a single phase, highlygraphitized composition subjected to intercalation of Li at above about50° C. Incorporation of an electrically conductive filamentary materialsuch as carbon black intimately interspersed with the carbonaceouscomposition minimizes capacity loss upon repeated cycling.

Otherwise, a known Li based negative electrode material is characterizedby comprising 1 m²/g or more of carbonaceous negative electrode activematerial specific surface area, a styrene-butadiene rubber binder, and afiber diameter formed to 1,000 nanometers of carbon fiber. Such negativeelectrode materials are used for Li batteries, which have desirablecharacteristics, such as a low electrode resistance, high strength ofthe electrode, an electrolytic solution having excellent permeability,high energy density and a high-rate charge/discharge. The negativeelectrode material contains 0.05 to 20 mass % of carbon fibers and astyrene at 0.1 to 6.0% by mass. Butadiene rubber forms the binder andmay further contain 0.3 to 3% by mass thickener, such as carboxymethylmethylcellulose.

Still further, existing technologies relate to a battery that has ananode active material that has been: (1) pre-lithiated; and (2)pre-pulverized. This anode may be prepared with a method that comprises:(a) providing an anode active material; (b) intercalating or absorbing adesired amount of Li into the anode active material to produce apre-lithiated anode active material; (c) comminating, referring to thereduction of solid materials from one average particle size to a smalleraverage particle size, by crushing, grinding, cutting, vibrating, orother processes, the pre-lithiated anode active material into fineparticles with an average size less than 10 μm (preferably <1 μm andmost preferably <200 nm); and, (d) combining multiple fine particles ofthe pre-lithiated anode active material with a conductive additiveand/or a binder material to form the anode. The pre-lithiated particlesare protected by a Li ion-conducting matrix or coating material. Thematrix material is reinforced with nano graphene platelets.

Graphitic nanofibers have also been disclosed and include tubularfullerenes (commonly called “buckytubes”), nano tubes and fibrils, whichare functionalized by chemical substitution, are used as electrodes inelectrochemical capacitors. The graphitic nanofiber-based electrodeincreases the performance of the electrochemical capacitors. Preferrednanofibers have a surface area greater than about 200 m²/gm and aresubstantially free of micropores.

And, known high surface area carbon nanofibers have an outer surface onwhich a porous high surface area layer is formed. Methods of making thehigh surface area carbon nanofiber include pyrolyzing a polymericcoating substance provided on the outer surface of the carbon nanofiberat a temperature below the temperature at which the polymeric coatingsubstance melts. The polymeric coating substance used as the highsurface area around the carbon nanofiber may include phenolics such asformaldehyde, polyacrylonitrile, styrene, divinyl benzene, cellulosicpolymers and cyclotrimerized diethynyl benzene. The high surface areapolymer which covers the carbon nanofiber may be functionalized with oneor more functional groups.

System Structure Point-of-Use Battery System

FIGS. 1A-1B show an exploded view of layers of a printed battery, suchlayers including elements of a cathode and anode portion, respectively.Such a stacked (such as “sandwiched”) architecture of a battery 100B(shown implemented in package 300A) as shown here includes elements of acathode portion and an anode portion. The cathode portion may include anelectrolyte layer 140B and a cathode 106B in a vertically stacked andadjacent configuration shown adhered to substrate 108B by seal 107B.Likewise, similar to cathode portion 111B, anode portion 110B may alsoinclude substrate 101B adhered to anode 104B via seal 103B.

Each the anode and cathode portions may include collectors 102B, 109Bthat are 3D printed substrates 101B, 108B, respectively. In theimplementation shown in FIGS. 1A-1B, electrolyte layer 105B is shown asbeing included on the cathode portion, although in other implementationsthe electrolyte may be incorporated within the cathode 106B. Eachelectrode, such as anode 104B and cathode 106B, is shown in FIGS. 1A-1Bas being a layer positioned between current collectors 102B, 109B,respectively and the electrolyte layer 105B. Seals 103B, 107B can defineperimeters (described in further detail below) that constrain spreadingof electrolyte 105B and/or electrode materials when the battery isactivated. Printed substrate surrounding battery 100B may serve as seals103B, 107B, while in other implementations seals 303B, 107B may beformed from another substance deposited onto the substrate.

FIGS. 1C1-1C2 show folding techniques related to activating aspects ofthe printed battery shown in FIGS. 1A-1B, FIGS. 1D1-1D3 show exampleprinted battery features, and FIG. 1E shows a flowchart related to amethod for activating an example printed battery.

FIG. 2 shows an example schematic for a traditional Li ion batteryincorporating the presently disclosed 3D self-assembled binder-lessmesoporous carbon-based particles. An example Li ion secondaryelectrochemical cell (battery) system 200 is shown in FIG. 2 , having ananode 203 and cathode 202 separated by separator 217, all at leastpartially contained and/or exposed to (Li) ion-conducting electrolytesolution 238 (containing dissociated lithium ion conducting salt 202) asshown. The separator, a porous membrane to electrically isolate the twoelectrodes from each other, is also in the position showed. Singlelithium ions migrate through pathway 207 back and forth between theelectrodes of the lithium ion-battery during charging and dischargingand are intercalated into the active materials.

During discharging, when lithium is deintercalated from the negativeelectrode (anode 203 and/or hierarchical mesoporous carbon-based anode203, where copper functions as the current collector), electrons 206 arereleased. The active materials of the positive electrode (cathode 202and/or hierarchical mesoporous carbon-based cathode 204) are, forexample, mixed oxides. Those of the negative electrode are graphite andamorphous carbon compounds. The positive electrode (cathode 202 and/orhierarchical mesoporous carbon-based cathode 204) contains activematerials such as mixed oxides. The active materials of the negativeelectrode (anode 203 and/or hierarchical mesoporous carbon-based anode203) are graphite and amorphous carbon compounds. These are thematerials into which the lithium is intercalated.

Notably, lithium ion conducting salt 202 (also referring to Li ionsgenerally) can intercalate into any one or more of the uniquecarbon-based structures (referring the mesoporous carbon-based particle300A, 300E, carbon-scaffold 300H, and lithiated carbon-scaffold 400Aand/or the like employed as an anode 203, replacing traditional anode203, and/or a cathode 204, replacing traditional cathode 202) all ofwhich are proprietary to LytEn, Inc., of Sunnyvale, Calif., to achievesurprising and wholly unexpected specific capacity retention capabilityfar in excess of the 372 mAh/g values commonly cited in traditional Liion battery related technologies, inclusive of performance at a level 3×or greater (referring to specific capacity retention capabilitiesexceeding 3,300 mAh/g or more), all made possible through the unique,multi-modal, hierarchical pores 303A and/or 307F defined by open porousscaffold 302A of mesoporous carbon-based particle 300A and/or 300E. Liions form complexes and/or compounds with S, for example, and aretemporarily retained during charge-discharge cycles at levels nototherwise achievable through conventional unorganized carbon structuresrequiring adhesive definition and combination via a binder, which can(as discussed earlier) also inhibit overall battery performance andlongevity.

Lithium ions migrate from the negative electrode (anode 203 and/orhierarchical mesoporous carbon-based anode 203, any one or more of whichfurther include and/or are defined by mesoporous carbon based particles300A and/or 300E with minute carbon particles 209 interspersed therein)through the electrolyte 238 and the separator 217 to the positiveelectrode (cathode 202 and/or hierarchical mesoporous carbon-basedcathode 204, any one or more of which further include and/or are definedby mesoporous carbon based particles 300A and/or 300E with minute carbonparticles 209 interspersed therein) ([using] aluminium as a currentcollector). Here, lithium metal 234 micro-confined (as shown in enlargedareas 236 and 233) within hierarchical mesoporous carbon-based anode 203(and in between graphene sheets 232 associated therewith as shown inarea 233) may dissociate pursuant to the following equation (3):

FLG-Li→FLG+Li+e−  (1)

Eq. (3) shows electrons 233 discharging 208 to power an external loadand lithium ions 232 migrating to cathode 202 and/or hierarchicalmesoporous carbon-based cathode 204 to return to a thermodynamicallyfavored position within a cobalt oxide-based lattice pursuant to thefollowing equation (2):

xLi⁺ +xe ⁻+Li_(3-x)CoO₂→LiCoO₂.  (2)

During charging, this process is reversed, where lithium ions 202migrate from the positive electrode through the electrolyte and theseparator to the negative electrode.

Disclosed carbon-based structures (referring to the surprising favorablespecific capacity values made possible by the unique multi-modalhierarchical structures of mesoporous carbon-based particle 300A, 300Eand/or derivatives thereof, including carbon scaffold 300H and lithiatedcarbon scaffold 400A) build upon traditional advantages offered bylithium-ion technology. Compared to sodium or potassium ions, the smalllithium ion exhibits a significantly quicker kinetics in the differentoxidic cathode materials. Another difference: as opposed to otheralkaline metals, lithium ions can intercalate and deintercalatereversibly in graphite and silicon. Furthermore, a lithiated graphiteelectrode enables very high cell voltages. Disclosed carbon-basedstructures uniquely and unexpectedly enhance the ease through whichlithium ions can intercalate and deintercalate reversibly betweengraphene sheets, due to the unique lay-out of few-layer graphene (FLG)(2-32 layers of graphene in a generally horizontally stackedconfiguration) 303C as employed in mesoporous carbon-based particle 300Aand/or the like, and are suitable for application in traditionalcylindrical (hardcase), pouch cell (softpack), and prismatic (hardcase)applications.

3D Self-Assembled Binder-Less Multi-Modal Mesoporous Carbon-BasedParticle-In Detail

FIGS. 3A-3H show illustrative schematic representations, at variousmagnification levels, and/or micrographs of a 3D self-assembledbinder-less 3D mesoporous carbon-based particle having tunableelectrical pathways and ionic conduits throughout the thickness thereof.

FIG. 3A shows a three-dimensional (3D) self-assembled binder-lessmulti-modal mesoporous carbon-based particle 300A having controllableelectrical and ionic conducting gradients distributed throughout, withinwhich various aspects of the subject matter disclosed herein may beimplemented. A mesoporous material, as generally understood and asreferred to herein, implies a material containing pores with diametersbetween 2 and 50 nm. For the purposes of comparison, IUPAC definesmicroporous material as a material having pores smaller than 2 nm indiameter and macroporous material as a material having pores larger than50 nm in diameter.

Mesoporous materials may include various types of silica and aluminathat have similarly sized mesopores. Mesoporous oxides of niobium,tantalum, titanium, zirconium, cerium and tin have been researched andreported. Of all the variants of mesoporous materials, mesoporous carbonhas achieved particular prominence, having direct applications in energystorage devices. Mesoporous carbon is defined as having porosity withinthe mesopore range, and this significantly increases the specificsurface area. Another common mesoporous material is “activated carbon”,referring to a form of carbon processed to have small, low-volume poresthat increase the surface area. Activated carbon, in a mesoporouscontext, is typically composed of a carbon framework with bothmesoporosity and microporosity (depending on the conditions under whichit was synthesized). According to IUPAC, a mesoporous material can bedisordered or ordered in a mesostructure. In crystalline inorganicmaterials, mesoporous structure noticeably limits the number of latticeunits, and this significantly changes the solid-state chemistry. Forexample, the battery performance of mesoporous electroactive materialsis significantly different from that of their bulk structure.

Mesoporous carbon-based particle 300A is nucleated and grown in anatmospheric plasma-based vapor flow stream of reagent gaseous species,which may include methane (CH₄), to form an initial carbon-containingand/or carbon-based particle. That initial particle may be expanded uponeither:

-   -   (1) “in-flight”, describing the systematic coalescence (to        nucleate from an initially formed seed particle) of additional        carbon-based material derived from incoming carbon-containing        gas mid-air within a microwave-plasma reaction chamber (as shown        by micrograph 300D in FIG. 1D); or,    -   (2) grown (and/or deposited) directly onto a supporting or        sacrificial substrate, such as a current collector, within a        thermal reactor.

In chemistry-related context, “coalescence” implies a process in whichtwo phase domains of the same composition come together and form alarger phase domain. Alternatively put, the process by which two or moreseparate masses of miscible substances seem to “pull” each othertogether should they make the slightest contact. Mesoporous carbon-basedparticle 300A, may also be referred to as a “particle.” The term“mesoporous” may be defined as a material containing pores withdiameters between 2 and 50 nm, according to International Union of Pureand Applied Chemistry (“IUPAC”) nomenclature.

Referring to synthesis and/or growth of mesoporous carbon-based particle300A within a reaction chamber in and/or otherwise associated with amicrowave-based reactor, such as a reactor disclosed in U.S. Pat. No.9,767,992 entitled “Microwave Chemical Processing Reactor,” which isincorporated by reference herein in its entirety, or thermal reactor,referring generally to a chemical reactor defined by an enclosed volumein which a temperature-dependent chemical reactor occurs.

Mesoporous carbon-based particle 300A (also mesoporous carbon-basedparticle 300E as shown in FIG. 1E) is synthesized with athree-dimensional (3D) hierarchical structure comprising short range,local nano-structuring in combination with long range approximatefractal feature structuring, which in this context refers to theformation of successive layers involving the 90—degree rotation of eachsuccessive layer relative to the one beneath it, and so on and so forth,allowing for the creation of vertical (or substantially vertical) layersand/or intermediate (“inter”) layers.

The plurality of hierarchical (and/or contiguous) pores 307F (as shownin FIG. 1F) at least in part further define open porous scaffold 302Awith one or more Li ion diffusion pathways 309F (as shown in FIG. 1F)having:

-   -   (1) microporous frameworks defined by a dimension 303F of >50 nm        that provide tuneable Li ion conduits;    -   (2) mesoporous channels defined by a dimension 303F of about 20        nm to about 50 nm (defined under IUPAC nomenclature and referred        to as “mesopores” or “mesoporous”) that act as Li ion-highways        for rapid Li ion transport therein; and    -   (3) microporous textures defined by a dimension 103F of <4 nm        for charge accommodation and/or active material confinement.

Li ion diffusion pathways 309F and/or hierarchical porous network 100Fmore generally may act as or otherwise provide active Li intercalatingstructures, which may provide a source for specific capacity of an anodeor cathode Li ion battery electrode at between about 744 mAh/g to about1,116 mAh/g. Li may infiltrate open porous scaffold to at leastpartially chemically react with exposed carbon therein. Mesoporouscarbon-based particle 300A may be synthesized at least in part by avapor flow stream of gaseous reagents including any one or more of asaturated or unsaturated hydrocarbon, such as methane (CH₄), flowed ontoa substrate in a reactor, such as a microwave-based reactor and/or athermal reactor.

One or more physical, electrical, chemical and/or material properties ofthe mesoporous carbon-based particle 300A may be defined during itssynthesis. Also, dopants (referring to traces of impurity element thatis introduced into a chemical material to alter its original electricalor optical properties, such as Si, SiO, SiO₂, Ti, TiO, Sn, Zn, and/orthe like) may be dynamically incorporated during synthesis of mesoporouscarbon-based particle 300A to at least in part affect materialproperties including: electrical conductivity, wettability, and/or ionconduction or transport through hierarchical porous network 100F.Microporous textures having dimension 103F and/or hierarchical porousnetwork 100F more generally may be synthesized, prepared or otherwisecreated to also (or otherwise) include smaller pores for chemicalmicro-confinement, the smaller pores being defined as ranging from 1 to3 nm. Also, each graphene sheet (as shown in FIG. 1C) may range from 50to 200 nm in diameter (L_(a)).

Hierarchical porous network 100F, may be a further magnified and/ordetailed variant of open porous scaffold 302A, may provide one or moreactive Li intercalating structures, to be further described in structureand/or functionality in connection with FIGS. 6-19C, which show varioustopic diagrams, flowcharts, schematics, photographs and/or micrographsrelated to lithium, lithium ion, sulphide, and/or lithium, sulfur and/orother element derived chemical substances and/or compounds infiltratedand/or infused into the multi-layered carbon-based scaffolded structureshown in FIG. 4B. Open porous scaffold 302A may be created independentof a binder, such as a traditional, nonconductive polymer bindertypically used in conjunction with and a conductive additive onto ametal foil current collector in battery end-use applications.Traditional configurations involving usage of a binder can lead toelectronic/current conduction-related or ionic constrictions and poorcontacts due to randomly distributed conductive phases. Moreover, whenhigh-capacity electrode materials are employed, relatively high physicalstress generated during electrochemical reactions can disrupt mechanicalintegrity of traditional binder systems, therefore, in turn, reducingcycle life of batteries.

A vapor flow stream used to synthesize mesoporous carbon-based particle300A may be flowed in part into a vicinity of a plasma, such as thatgenerated and/or flowed into a reactor and/or chemical reaction vessel.Such a plasma reactor may be configured to propagate microwave energytoward the vapor flow stream to at least in part assist with synthesisof mesoporous carbon-based particle 300A, may involve carbon-particlebased and/or derived nucleation and growth from constituent carbon-basedgaseous species, such as methane (CH₄), where such nucleation and growthmay substantially occur from an initially formed seed particle within areactor. More particularly, such a reactor accommodates control ofgas-solid reactions under non-equilibrium conditions, where thegas-solid reactions may be controlled at least in part by any one ormore of:

-   -   (1) ionization potentials and/or thermal energy associated with        constituent carbon-based gaseous species introduced to the        reactor for synthesis of the mesoporous carbon-based particle;        and/or    -   (2) kinetic momentum associated with the gas-solid reactions.

The vapor flow stream may be flowed into a reactor and/or reactionchamber for the synthesis of mesoporous carbon-based particle 300A atatmospheric pressure. And change in wettability of mesoporouscarbon-based particle 300A (and/or any constituent members such as openporous scaffold 302A) at least in part may involve adjustment ofpolarity of a carbon matrix associated with mesoporous carbon-basedparticle 300A.

Those skilled in the art will appreciate that the representationsprovided in FIGS. 1A-1D, 1E and 1F, are provided as examples. Samplerepresentations are shown of mesoporous carbon-based particle 300A,including:

-   -   (1) when synthesized in a microwave-based reactor in micrograph        300D in FIG. 3D;    -   (2) when synthesized in the form of multi-shell fullerene (CNO);    -   (3) when used to decorate graphite to form graphene-decorated        graphite; and,    -   (4) when synthesized in-flight in a microwave reactor.

Mesoporous Carbon-Based Particle-Procedures for Synthesis MicrowaveReactor

As introduced above, a vapor flow stream including carbon-containingconstituent species, such as methane (CH₄) may be flowed into one of twogeneral reactor types:

-   -   (1) a thermal reactor; or,    -   (2) a microwave-based (and/or “microwave”) reactor. Suitable        types of microwave reactors are disclosed in U.S. Pat. No.        9,767,992.

An example microwave processing reactor used to synthesize mesoporouscarbon-based particle 300A may include microwave-generating energysource and a field-enhancing waveguide. The field-enhancing waveguidehas a field-enhancing zone between a first cross-sectional area and asecond cross-sectional area of the waveguide, and also has a plasma zoneand a reaction zone. The second cross-sectional area is smaller than thefirst cross-sectional area, is farther away from the microwave energysource than the first cross-sectional area and extends along a reactionlength of the field-enhancing waveguide. The supply gas inlet isupstream of the reaction zone. In the reaction zone, a majority of thesupply gas flow is parallel to the direction of the microwave energypropagation. The supply gas is used to generate a plasma in the plasmazone to convert a process input material into separated components inthe reaction zone at a pressure of at least 0.1 atmosphere, with apreference for 1 atmosphere where the favorable physical properties ofmesoporous carbon-based particle 300A, as discussed above, werediscovered.

Propagation of microwave energy toward the carbon-containing orcarbon-based vapor flow stream at least in part assists with synthesisof mesoporous carbon-based particle 300A and facilitates carbon-particlenucleation and growth within a reactor.

The term “in-flight” implies a novel method of chemical synthesis basedon contacting particulate material derived from inflowingcarbon-containing gaseous species, such as those containing methane(CH₄), to “crack” such gaseous species. “Cracking”, as generallyunderstood and as referred to herein, implies the technical process ofmethane pyrolysis to yield elemental carbon, such as high-quality carbonblack, and hydrogen gas, without the problematic contamination by carbonmonoxide, and with virtually no carbon dioxide emissions. A basicendothermic reaction that may occur within a microwave reactor isexpressed as equation (1) below:

CH₄+74.85 kJ/mol→C+2H₂  (1)

Carbon derived from the above-described “cracking” process and/or asimilar or a dissimilar process may fuse together while being dispersedin a gaseous phase, referred to as “in-flight”, to create carbon-basedparticles, structures, (substantially) 2D graphene sheets, 3Dagglomerations, and/or pathways defined therein, including:

-   -   (1) a plurality of interconnected 3D agglomerations 303B of        multiple layers of graphene sheets 303C (also, each sheet of        graphene is schematically depicted in FIG. 1C) that are sintered        together to form an open porous scaffold 302A that facilitates        electrical conduction along and across contact points of the        graphene sheets 303C (which, as shown in FIG. 1B, may include        and/or refer to 5 to 15 layers of graphene are oriented in a        stacked configuration to have a vertical height referred to as a        stack height (L_(c))); and,    -   (2) a plurality of hierarchical pores 307F (as shown in FIG. 1F,        and including pores 304F, 305F, and/or pathways 306F and/or        309F, any one or more which may be of a different dimension than        the others) interspersed with the plurality of interconnected 3D        agglomerations 303B of multiple layers of graphene sheets 303C,        that may comprise one or more of single layer graphene (SLG),        few layer graphene (FLG) defined as ranging from 5 to 15 layers        of graphene, or many layer graphene (MLG), throughout the        multi-modal mesoporous carbon-based particle 300A and/or 300E to        define a hierarchical porous network 100F that facilitates rapid        Li ion (Li+) 108F diffusion therein by orienting and/or        manipulating, such as by shortening, Li ion diffusion pathways        306F and/or 309F.

As introduced earlier, interconnected 3D agglomerations of multiplelayers of graphene sheets 303B sinter (or otherwise adjoin) together toserve as a type of intrinsic, self-supporting, “binder” or joiningmaterial allowing for the elimination of a separate traditional bindermaterial. Sintering, or “frittage,” as commonly understood and asreferred to herein, implies the process of compacting and forming asolid mass of material by heat or pressure without melting it to thepoint of liquefaction. Sintering happens naturally in mineral depositsor as a manufacturing process used with metals, ceramics, plastics, andother materials. The atoms in the materials diffuse across theboundaries of the particles, fusing the particles together and creatingone solid piece. Since sintering temperature does not have to reach themelting point of the material, sintering may be chosen as the shapingprocess for materials with extremely high melting points such astungsten (W) and molybdenum (Mo). The study of sintering in metallurgypowder-related processes is known as powder metallurgy. An example ofsintering is when ice cubes in a glass of water adhere to each other,which is driven by the temperature difference between the water and theice. Examples of pressure-driven sintering are the compacting ofsnowfall to a glacier, or the forming of a hard snowball by pressingloose snow together.

Few layer graphene (FLG), defined herein as ranging from 5 to 15 layersor sheets of graphene, can sintered, as so-described above, at an anglethat is not flat relative to other FLG sheets to nucleate and/or grow atan angle and therefore “self-assemble” over time. Alternativeconfigurations can exist where techniques other than sintering areemployed (or at least partially employed in conjunction with sintering),such as fusing of the FLG sheets to each other at defined right degreeangles to define an orthogonally grown carbon-based structure, scaffold,matrix, sponge and/or the like. Moreover, process conditions may betuned to achieve synthesis, nucleation, and/or growth of 3D multi-modalmesoporous carbon-based particles on a component and/or a wall surfacewithin a reaction chamber, or entirely in-flight (upon contact withother carbon-based materials).

Electrical conductivity of deposited carbon and/or carbon-basedmaterials may be tuned by adding metal additions into the carbon phasein the first part of the deposition phase or to vary the ratios of thevarious particles discussed. Other parameters and/or additions may beadjusted, as a part of an energetic deposition process, such that thedegree of energy of deposited carbon and/or carbon-based particles willeither: (1) bind together; or (2) not bind together.

By nucleating and/or growing the multi-modal mesoporous carbon-basedparticle in an atmospheric plasma-based vapor flow stream eitherin-flight or directly onto a supporting or sacrificial substrate, anumber of the steps and components found in both traditional batteriesand traditional battery-making processes may be eliminated. Also, aconsiderable amount of tailoring and tunability can be enabled orotherwise added into the discussed carbons and/or carbon-basedmaterials.

For instance, a traditional battery may use a starting stock of activematerials, graphite, etc., which may be obtained as off-the-shelfmaterials to be mixed into a slurry. In contrast, the 3D self-assembledbinder-less multi-modal mesoporous carbon-based particle 300A disclosedherein may enable, as a part of the carbon or carbon-based materialsynthesis and/or deposition process, tailoring and/or tuning theproperties of materials, in real-time, as they are being synthesizedin-flight and/or deposited onto a substrate. This capability presents asurprising, unexpected, and substantial favorable departure from thatcurrently available regarding creation of carbon-based scaffoldedelectrode materials in the secondary battery field.

Reactor and/or reactor designs disclosed in U.S. Pat. No. 9,767,992 maybe adjusted, configured and/or tailored to control wanted or unwantednucleation sites on internal surfaces of reaction chambers exposed tocarbon-based gaseous feedstock species (such as methane (CH₄)).In-flight particles qualities may be influenced by their solubility inthe gaseous species in which they are flowed in such that once a certainenergy level is achieved, the carbon may “crack off” (as so described by“cracking”) and form its own solid in a microwave reactor.

Adjusting for Unwanted Carbon Accumulation on Reaction Chamber Walls

Moreover, tuning of disclosed reactors and related systems may beperformed to both proactively and reactively address issues associatedwith carbon-based microwave reactor clogging. For instance, opensurfaces, feed holes, hoses, piping, and/or the like may accumulateunwanted carbon-based particulate matter as a by-product of syntheticprocedures performed to create mesoporous carbon-based particle 300A. Acentral issue observed in a microwave reactor may include this tendencyto experience clogging in and/or along orifices, the reason beingrelated to walls and other surfaces exposed to in-flowing gaseouscarbon-containing species having carbon solubility as well. Therefore,is it possible to unwantedly grow on the walls of a reaction chamberand/or on the exit tube. Over time, those growths will extend out andimpinge flow and can shut down chemical reactions occurring within thereactor and/or reaction chamber. Such a phenomena may be akin to tube(exhaust) wall build-up of burnt oil in a high-performance or racinginternal combustion engine, where, instead of burning (combusting)fossil-fuel based gasoline, methane is used to result in the unwanteddeposit of carbon on reaction chamber wells since metal inside thereaction chamber itself has a carbon solubility level.

Although methane is primarily used to create mesoporous carbon-basedparticle 300A, in theory any carbon-containing and/or hydrocarbon gas,like C₂ or acetylene or any one or more of: C₂H₂, CH₄, butane, naturalgas, biogas, derived from decomposition of biological matter, willfunction to provide a carbon-containing source.

The described uncontrolled and unwanted carbon growth within exposedsurfaces of a microwave reactor may be compared to that occurring withinan internal combustion engine exhaust manifold, rather than within acylinder bore, of the engine, especially where the plume of plasma,and/or hot, excited gas about to enter into the plasma phase, is at theonset of the manifold, and burnt gas and carbon-based fragments aretraveling down and plugging-up flow through the manifold, cross-pipes,and catalytic converter, and exit-pipes. Process conditions maytherefore be proactively tuned to adjust and therefore accommodate forpotential carbon-build-up as so-described in the microwave reactor,which relies on the presence of a plasma for hydrocarbon gas cracking.To maintain this plasma, a certain set of conditions must be maintained,otherwise back-pressure accumulation can potentially destroy the plasmaprior to its creation and subsequent ignition, etc.

Thermal Reactor

In the alternative (or in certain cases, in addition or combinationwith) synthesis of mesoporous carbon-based particle 300A in amicrowave-based and/or microwave reactor as substantially describedabove, specifically structured and/or scaffolded carbons and/orcarbon-based structures can be created by “cracking” hydrocarbons purelyby heat application in a reactor featuring application of thermalradiation, such as heat, referred to herein as a “thermal reactor”.Example configurations may include exposure of incoming carbon-basedgaseous species, such as any one or more of the aforementionedhydrocarbons, to a heating element, similar to a wire in a lightbulb.

The heating element heats up the inside of a reaction chamber whereincoming carbon-containing gas is ionized. The carbon-containing gas isnot burnt, due to the absence of sufficient oxygen to sustaincombustion, but is rather ionized from contact with incoming thermalradiation, alternatively referred to as heat, and/or other forms ofthermal energy to cause nucleation of constituent members of mesoporouscarbon-based particle 300A, and ultimately synthesize, via nucleation,mesoporous carbon-based particle 300A in its entirety. In thermalreactors, some, or most, of the observed nucleation of carbon-basedparticles can occur on walls or on the heating element itself.Nevertheless, particles can still nucleate which are small enough to becracked by the speed of flowing gas, such particles are captured toassist in the creation of mesoporous carbon-based particle 300A.

Cracked carbons can be used to create CNO as shown, for example, by 100Hin FIG. 1H, and/or fullerenes, and smaller fractions of carbons withfullerene internal crystallography.

In comparing synthesis of mesoporous carbon-based particle 300A via thetwo discussed pieces of equipment, microwave and thermal reactors, thefollowing distinctions have been observed:

-   -   (1) microwave reactors can provide tuning capabilities suitable        to provide a broader range of allotropes of carbon; whereas,    -   (2) thermal reactors tend to allow for the fine-tuning of        process parameters, such as heat flow, temperature, and/or the        like, to achieve the needs of specific end-use application        targets of mesoporous carbon-based particle 300A.

For instance, thermal reactors are currently being used to build Li Selectrochemical cell electrodes, such as anodes and cathodes. Typicaltreatment process temperatures range in the thousands of Kelvin, withoptimal, surprising, and otherwise unexpected favorable performanceproperties, such as referring to mesoporous carbon-based particle 300Aand/or carbon-based aggregates associated therewith, when compressed,have an electrical conductivity greater than 500 S/m, or greater than5,000 S/m, or from 500 S/m to 20,000 S/m. Optimal performance has beenobserved at between 2,000-4,000 K.

Mesoporous Carbon-Based Particle-Physical Properties & Implementation inBatteries

Any one or more of the carbon-based structures, intermediaries, orfeatures associated with mesoporous carbon-based particle 300A may beincorporated at least in part into a secondary battery electrode, suchas that of a lithium-ion battery, as substantially set forth in U.S.Patent Publication 2019/0173125, which is incorporated by referenceherein in its entirety.

Particulate carbon contained in and/or otherwise associated withmesoporous carbon-based particle 300A may be implemented in a Li ionbattery cathode as a structural and/or electrically conductive materialand have at least a substantially a mesoporous structure as shown byhierarchical porous network 100F with a wide distribution of pore sizes(also referred to as a multi-modal pore size distribution). For example,mesoporous particulate carbon can contain multi-modal distribution ofpores in addition or in the alternative to plurality of hierarchicalpores 307F (as shown in FIG. 3F) that at least in part further defineopen porous scaffold 302A with one or more Li ion diffusion pathways309F. Such pores may have sizes from 0.1 nm to 10 nm, from 10 nm to 100nm, from 100 nm to 1 micron, and/or larger than 1 micron. Porestructures can contain pores with a bi-modal distribution of sizes,including smaller pores (with sizes from 1 nm to 4 nm) and larger pores(with sizes from 30 to 50 nm). Such a bimodal distribution of pore sizesin mesoporous carbon-based particle 300A can be beneficial insulfur-containing cathodes in lithium ion batteries, as the smallerpores (1 to 4 nm in size) can confine the sulfur (and in some casescontrol of saturation and crystallinity of sulfur and/or of generatedsulfur compounds) in the cathode, and the larger pores (30 to 50 nm insize, or pores greater than twice the size of solvated lithium ions) canenable and/or facilitate rapid diffusion (or, mass transfer) of solvatedLi ions in the cathode.

As discussed, the lithium-sulfur battery (Li—S battery) is a type ofrechargeable battery, notable for its high specific energy. Alithium/sulfur (Li/S) battery (such as that represented by sulfur (S)infiltrated into hierarchical pores 307F of mesoporous particle 300E(such as where S infiltrates open porous scaffold 302A to deposit oninternal surfaces of mesoporous carbon-based particle 300A, 300E and/orwithin pores 307F), as shown in at least FIGS. 3A and 3E respectively,and by schematic 300G shown in FIG. 1G, showing intermediate stepsassociated with the reduction of sulfur to the sulfide ion (S²⁻).Incorporation of S into Li ion batteries may result in a 3-5 fold highertheoretical energy density than state-of-art Li ion batteries without S,and research has been ongoing for more than three decades. However, thecommercialization of Li/S battery still, in some respects, cannot befully realized due to many problematic issues, including short cyclelife, low cycling efficiency, poor safety and a high self-dischargerate. All these issues are related to the dissolution of lithiumpolysulfide (PS), the series of sulfur reduction intermediates, inliquid electrolyte and to resulting parasitic reactions with the lithiumanode and electrolyte components. On the other hand, the dissolution ofPS is essential for the performance of a Li/S cell. Without dissolutionof PS, the Li/S cell cannot operate progressively due to thenon-conductive nature of elemental sulfur and its reduction products.

Mesoporous Carbon-Based Particle-Formed to Address Polysulfide(PS)—Related Challenges

Seeking to address at least some of the challenges associated with suchpolysulfide (PS) systems, mesoporous carbon-based particle 300A andcathodic active material form a meta-particle framework, where cathodicelectroactive materials (such as elemental sulfur that may form PScompounds 300G as shown in FIG. 1G) are arranged within mesoporouscarbon pores/channels, such as within any one or more of hierarchicalpores 307F (as shown in FIG. 1F, including pores 304F, 305F, and/orpathways 306F and/or 309F). S can be, for example, incorporated withinpores 307F at a loading level that represents 35-100% of the totalweight/volume of active material in mesoporous carbon-based particle300A and/or 300E overall.

This type of organized particle framework can provide a low resistanceelectrical contact between the insulating cathodic electroactivematerials (such as elemental sulfur) and the current collector whileproviding relatively high exposed surface area structures that arebeneficial to overall specific capacity (and that may be at least assistlithium ion micro-confinement as enhanced by the formation of Li Scompounds temporarily retained in hierarchical pores 307F, and thecontrolled release and migration of Li ions as related to electriccurrent conduction) in a battery electrode and/or system.Implementations of mesoporous carbon-based particle 300A can alsobenefit cathode stability by trapping at least some portion of anycreated polysulfides by using tailored structures, such as that shown byhierarchical pores 307F, to actively prevent them from unwantedlymigrating through electrolyte to the anode resulting in unwantedparasitic chemical reactions associated with battery self-discharge.

Unwanted Migration of Polysulfides During Li S Battery SystemUsage—Generally

With reference to polysulfide shuttle mechanisms observed in Li Sbattery electrodes and/or systems, polysulfides dissolve very well inelectrolytes. This causes another lithium-sulfur cell characteristic,the so-called shuttle mechanism. The polysulfides S_(n2)—that form anddissolve at the cathode, diffuse to the lithium anode and are reduced toLi₂S₂ and Li₂S. (The polysulfide species S_(n)2— that form at thecathode during discharging dissolve in the electrolyte there. Aconcentration gradient versus the anode develops, which causes thepolysulfides to diffuse toward the anode. Step by step, the polysulfidesare distributed in the electrolyte.) Subsequent high-order polysulfidespecies react with these compounds and form low-order polysulfidesS_((n-x)). This means that the desired chemical reaction of sulfur atthe cathode partly also takes place at the anode in an uncontrolledfashion (chemical or electrochemical reactions are conceivable), whichnegatively influences cell characteristics.

If low-order polysulfide species form near the anode, they diffuse tothe cathode. When the cell is discharged, these diffused species arefurther reduced to Li₂S₂ or Li₂S. Simply put, the cathode reactionpartly takes place at the anode during the discharging process or,rather, the cell self-discharges. Both are undesirable effectsdecreasing [specific] capacity. In contrast, the diffusion to thecathode during the charging process is followed by a re-oxidation of thepolysulfide species from low order to high order. These polysulfidesthen diffuse to the anode again. This cycle is known as the shuttlemechanism. If the shuttle mechanism is very pronounced, it is possiblethat a cell can accept an unlimited charge, it is ‘chemically shortcircuited’.

In general, the shuttle mechanism causes a parasitic sulfur activematter loss. This is due to the uncontrolled separation of Li₂S₂ andLi₂S outside of the cathode area and it eventually causes a considerabledecrease in cell cycling capability and service life. Further agingmechanisms can be an inhomogeneous separation of Li₂S₂ and Li₂S on thecathode or a mechanical cathode structure breakup due to volume changesduring cell reaction.

Hierarchical Pores of Mesoporous Carbon-Based Particle to PreventLithium Shuttle

To address the unwanted phenomenon of PS shuttling as so describedabove, any one or more of the plurality of hierarchical pores 307F ofmesoporous carbon-based particle 300A in a cathode can provide asuitable region, formed with an appropriate dimension, to drive thecreation of lower order polysulfides (such as S and Li₂S) and thereforeprevent the formation of the higher order soluble polysulfides(Li_(x)S_(y) with y greater than 3) that facilitate lithium shuttle(such as loss) to the anode. As described herein, the structure of theparticulate carbon and the cathode mixture of materials can be tunedduring particulate carbon formation (within a microwave plasma orthermal reactor). In addition, cathodic electroactive materials(elemental sulfur) solubility and crystallinity in relation to lithiumphase formation, can be confined/trapped within the micro/meso porousframework.

The lithium-ion batteries disclosed herein can incorporate particulatecarbon as presented by mesoporous carbon-based particle 300A and/or anyderivatives thereof into the cathode, anode, and/or one or bothsubstrates with improved properties compared to conventional carbonmaterials. For example, the particulate carbon can have highcompositional purity, high electrical conductivity, and a high surfacearea compared to conventional carbon materials. In some implementations,the particulate carbon also has a structure that is beneficial forbattery properties, such as small pore sizes and/or a mesoporousstructure. In some cases, a mesoporous structure can be characterized bya structure with a wide distribution of pore sizes (with a multimodaldistribution of pore sizes). For example, a multimodal distribution ofpore sizes can be indicative of structures with high surface areas and alarge quantity of small pores that are efficiently connected to thesubstrate and/or current collector via material in the structure withlarger feature sizes (such as that provide more conductive pathwaysthrough the structure). Some non-limiting examples of such structuresare fractal structures, dendritic structures, branching structures, andaggregate structures with different sized interconnected channels(composed of pores and/or particles that are cylindrical and/orspherical).

In some implementations, the substrate, cathode, and/or anode containsone or more particulate carbon materials. In some implementations, theparticulate carbon materials used in the lithium-ion batteries disclosedherein may be those described in in U.S. Pat. No. 9,997,334, discussedabove. In some implementations, the particulate carbon materials containgraphene-based carbon materials that comprise a plurality of carbonaggregates, each carbon aggregate having a plurality of carbonnanoparticles, each carbon nanoparticle including graphene, optionallyincluding multi-walled spherical fullerenes, and optionally with no seedparticles (such as with no nucleation particle). In some cases, theparticulate carbon materials are also produced without using a catalyst.The graphene in the graphene-based carbon material has up to 15 layers.A ratio (such as percentage) of carbon to other elements, excepthydrogen, in the carbon aggregates is greater than 99%. A median size ofthe carbon aggregates is from 1 micron to 50 microns, or from 0.1microns to 50 microns. A surface area of the carbon aggregates is atleast 10 m²/g, or is at least 50 m²/g, or is from 10 m²/g to 300 m²/g oris from 50 m²/g to 300 m²/g, when measured using aBrunauer-Emmett-Teller (BET) method with nitrogen as the adsorbate. Thecarbon aggregates, when compressed, have an electrical conductivitygreater than 500 S/m, or greater than 5000 S/m, or from 500 S/m to20,000 S/m.

Mesoporous Carbon-Based Particle-Departure from Conventional Technologyto Yield Surprising Favorable Results

Conventional composite-type Li-ion or Li S battery electrodes (shown inFIG. 2B) may be fabricated from a slurry cast mixture of activematerials (shown as in FIG. 2A), including: conductive additives (suchas fine carbon black and graphite for usage in a battery cathode at aspecific aspect ratio), and polymer-based binders that are optimized tocreate a unique self-assembled morphology defined by an interconnectedpercolated conductive network. While, in conventional preparations orapplications, additives and binders can be optimized to improveelectrical conductivity there-through (by, for example, offering lowerinterfacial impedance) and therefore correspondingly yield improvementsin power performance (delivery), they represent a parasitic mass thatalso necessarily reduces specific (also referred to as gravimetric)energy and density, an unwanted end result for today's demandinghigh-performance battery applications.

To minimize losses due to parasite mass (such as that caused byincreased active and/or inactive ratio), and concurrently enable fasteraccess of electrolyte to the complete surface of an electrode,orienting, re-orienting, and/or otherwise organizing or repositioningion diffusion pathways 309F to effectively shorten Li ion diffusion pathlengths for charge transfer, hierarchical pores 303A and/or open porousscaffold 302A may be created from reduced-size carbon particles and/oractive materials (down to nanometer scales), since the external specificsurface area (SSA, defined as the total surface area of a material perunit of mass, (with units of m²/kg or m²/g) or solid or bulk volume(units of m²/m³ or m⁻¹); it is a physical value that can be used todetermine the type and properties of a material (soil or snow)) of asphere increases with decreasing diameter. However, as the particle sizeis decreased down into the nanometer size range there are associatedattractive van der Waal forces that can impede dispersion, facilitateagglomeration, and thereby increase cell impedance and reduce powerperformance.

Another approach to shortening ion diffusional pathways, referring toion diffusion pathways 309F shown in FIG. 1F, is to uniquely engineerthe internal porosity of the constitutive carbon-based particles, suchas those created by the electrically conductive interconnectedagglomerations of graphene sheets 303B to create open porous scaffold302A and/or define hierarchal pores 303A and/or 307F. As per commonlyused definitions, and as referred to herein, a “surface curvature” isreferred to as a “pore” if its cavity is deeper than it is wide. As aresult, this definition necessarily excludes many nanostructured carbonmaterials where just the external surface area is modified, or in closepacked particles where voids (intra-particular) are created betweenadjacent particles (as in the case of a conventional slurry castelectrode).

With respect to the engineering (referring to the synthesis, creation,formation, and/or growth of mesoporous carbon-based particle 300A eitherin-flight in a microwave-based reactor or via layer-by-layer depositionin a thermal reactor as substantially described earlier), reactorprocess parameters may be adjusted to tune the size, geometry, anddistribution of hierarchical pores 303A and/or 307F within mesoporouscarbon-based particle 300A. Hierarchical pores 303A and/or 307F withinmesoporous carbon-based particle 300A may be tailored to achieveperformance figures particularly well-suited for implementation inhigh-performance fast-current delivery devices, such as supercapacitors.

As generally described earlier, a supercapacitor (SC), also called anultracapacitor, is a high-capacity capacitor with a capacitance valuemuch higher than other capacitors, but with lower voltage limits, thatbridges the gap between electrolytic capacitors and rechargeablebatteries. It typically stores 10 to 100 times more energy per unitvolume or mass than electrolytic capacitors, can accept and delivercharge much, much faster than batteries, and tolerates many more chargeand discharge cycles than rechargeable batteries.

In many of the available off-the-shelf commercial carbons used in earlysupercapacitor development efforts, there were “worm”—like narrow poreswhich became a bottleneck or liability when operating at high currentdensities and fast charge- and discharge rates, as electrons mayencounter difficulty in flow through, in or around such structures orpathways. Even though pore dimensions were fairly uniform but stilladjustable to accommodate a wide range of length scales, real-lifeachievable performance was still self-limited (as based on thestructural challenges inherent to the “worm”—like narrow pores).

Compared to conventional porous materials with uniform pore dimensionsthat are tuned to a wide range of length scales, the presently disclosed3D hierarchical porous materials (such as that shown by hierarchicalpores 303A and/or 307F within mesoporous carbon-based particle 300A) maybe synthesized to have well-defined pore dimensions (such ashierarchical pores 307F including pores 304F, 305F, and/or pathways 306Fand/or 309F) and topologies overcome the shortcomings of conventional‘mono-sized’ porous carbon particles by creating, multi-modal (such asbi-modal) pores and/or channels having the following dimensions and/orwidths:

-   -   (1) meso (2 nm<d_(pore) 50 nm) pores; <    -   (2) macro (d_(pore)>50 nm) pores 303A (as shown in micrograph        300A of FIG. 3A) to minimize diffusive resistance to mass        transport; and,    -   (3) micro (d_(pore)<2 nm) pores 302A to increase surface area        for active site dispersion and/or ion storage (capacitance        relating to density and number of ions that can be stored within        a given pore size, such as that shown by pore 305F having        dimension 103F in FIG. 1F).

Although no simple linear correlation has been experimentallyestablished between: (1) surface area; and, (2) capacitance, mesoporouscarbon-based particle 300A offers surprising favorable results inproviding optimal micropore size distributions and/or configurations(such as when integrated into a Li ion or Li S battery electrode toachieve certain specific capacity and power values or ranges) that aredifferent for each intended end-use application (such as an electrolytesystem) and corresponding voltage window. To optimize capacitanceperformance, mesoporous carbon-based particle 300A may be synthesizedwith very narrow “pore size distributions” (PSD); and, as desired orrequired voltages are increased, larger pores are preferred. Regardless,current state-of-the-art supercapacitors have provided a pathway toengineering the presently disclosed 3D hierarchical structured materialsfor particular end-use applications.

In contrast to supercapacitors, where capacitance and power performanceis primarily governed by, for example:

(1) surface area of the pore wall;

(2) size of pore; and

(3) interconnectivity of the pore channels (which affect electric doublelayer performance)

Li-ion storage batteries undergo faradaic reduction/oxidation reactionswithin the active material and thereby may require not only all of theLi ion transport features of a supercapacitor (such as efficientlyoriented and/or shortened Li ionic diffusion pathways). Regardless, inany application (including a supercapacitor as well as a traditional Liion or Li S secondary battery) a 3D nanocarbon-basedframework/architecture (such as that defined open porous scaffold 302A)can provide continuous electrical conducting pathways (such as acrossand along electrically conductive interconnected agglomerations ofgraphene sheets 303B1 alongside, for example, highly-loaded activematerial having high areal and volumetric specific capacity.

Mesoporous Carbon-Based Particle—Used as a Formative Material for aCathode

To address prevailing issues with relatively low electrical and ionicconductivities, volume expansion and polysulfide (PS) dissolution(referring to the PS “shuttle” effect, discussed earlier, leading tolithium loss and capacity fade) in current sulfur cathode electrodedesigns, mesoporous carbon-based particle 300A has hierarchical pores303A and/or 307F formed therein to define open porous scaffold 302A,which includes pores 305F with microporous textures 103F having adimension (such as 1-4 nm cavities) suitable to at least temporarilymicro-confine elemental sulfur and/or Li S related compounds. Openporous scaffold 302A, at the same time as confining sulfur as sodescribed, also provides a host scaffold-type structure to manage sulfurexpansion to ensure surprising, unexpected, and highly desirableelectron transport across the sulfur-carbon interface (such as atcontact and/or interfacial regions of sulfur and carbon within pores305F) by, for example, tailored in-situ nitrogen doping of the carbonwithin the reactor. Confining sulfur within a nanometer scale cavity(such as pores 305F with microporous textures 103F) favorably altersboth:

-   -   (1) the equilibrium saturation (solubility product); and,    -   (2) crystalline behaviour of sulfur, such that sulfur remains        confined (as may be necessary for desirable electrical        conduction upon dissociation of Li S compounds, etc.) within        microporous textures having dimension 103F, with no external        driving force required to migrate to the anode electrode.

As a result, unique dimension 103F (including diameter, height and/orwidth of about 1-4 nm in cavity form as described above) provided bypores 305F results in no need for separators that attempt to impedepolysulfide diffusion while, at the same time, negatively impacting cellimpedance (referring to the effective resistance of an electric circuitor component to alternating current, arising from the combined effectsof ohmic resistance and reactance) and polarization. By using carbonwith optimum (relative to elemental sulfur, lithium and/or Li Smicro-confinement) and non-optimum multi-modal, referring tohierarchical pores 307F including pores 304F, 102F, and/or 103F, or(alternatively) bi-modal pore distributions, mesoporous carbon-basedparticle 300A demonstrates, unexpectedly and favorably, operation of theprinciple of micro-confinement in properly optimized (relative to finalend-use application specific demands) structures.

Along with creating delicately engineered ornate, hierarchicalmulti-modal carbon-based particles, such as mesoporous carbon-basedparticle 300A and organized scaffolds generated therefrom, mesoporouscarbon-based particle 300A further uniquely provides the ability toeffectively load or infuse carbon scaffold 300H shown in FIG. 3B (thatmay be created in-reactor by either:

-   -   (1) layer-by-layer deposition of multiple mesoporous        carbon-based particles 300A by a slurry-case method; or,    -   (2) by a continuous sequence of a group of plasma spray-torches,        as shown by plasma spray-torch system 400B in FIG. 4B), with        sulfur, such as elemental sulfur.

For lithium-sulfur battery performance to practically exceedconventional lithium-ion batteries, industry-scalable techniques mustachieve high sulfur loading (such as >70% sulfur per unit volume)relative to all additives and components of a given cathode template,while maintaining the native specific capacity of the sulfur activematerial. Attempts to incorporate sulfur into a cathode host, such as byany one or more of (performed independently or in any combination):electrolysis, wet chemical, simple mixing, ball milling, spray coating,and catholytes, have either not fully incorporated the sulfur asdesirable, or are otherwise not economically scalable or manufacturable.Unlike melt infiltration where small pores are thermodynamicallyinaccessible, presently disclosed synthetic approaches use an isothermalvapor technique, introduced and reacted at substantially atmosphericpressure, where the high surface free energy of nanoscale pores orsurfaces drives the spontaneous nucleation of sulfur containing liquidsuntil a conformal coating of sulfur and/or lithium-containing condensateis reached on inner-facing surfaces of hierarchical pores 303A and/or307F. In essence, unique vapor infusion process unexpectedly (andfavorably) completely infuses sulfur into fine pores (such as any one ormore of hierarchical pores 303A and/or 307F and/or pores 304F, 305Fand/or pathways 306F and/or 309F) at the core of mesoporous carbon-basedparticle 300A, and therefore not just at its surface.

Mesoporous Carbon-Based Particle to Create an Electrically ConductiveScaffold

Mesoporous carbon-based particle 300A, may be fabricated any number ofways using both known and novel techniques disclosed herein, including:

-   -   (1) slurry-casting, referring to conventional metalworking,        manufacturing and/or fabrication techniques in which a liquid        material is usually poured into a mold, which contains a hollow        cavity of the desired shape, and then allowed to solidify; or    -   (2) plasma spray-torch system 400B (shown in FIG. 4B), which may        be used to perform layer-by-layer deposition to grow mesoporous        carbon-based particle 300A incrementally.

Either (1) or (2) as described above, or any other known or novelfabrication techniques, may be used to create carbon scaffold 300H in a“graded” manner, referring to under specifically controlled conditionsresulting in corresponding control of:

-   -   (1) electrical gradients (referring to interconnected 3D        agglomerations of multiple layers of graphene sheets 303B that        are sintered together, as discussed earlier, to form open porous        scaffold 302A that facilitates electrical conduction along and        across contact points of graphene sheets 303B); and,    -   (2) ionic conductive gradients (referring Li ion transport        through hierarchical pores 303A and/or 307F, which are defined        by electrically conductive interconnected agglomerations of        graphene sheets 303B, and cause rapid lithium (Li) ion diffusion        effectively shortening Li ion diffusion pathways 309F)        throughout thickness of carbon scaffold 300H, in the vertical        height direction A as shown in FIG. 3B, of mesoporous        carbon-based particle 100.

Reference is made herein to various forms of carbon and/or graphenesynthesized in-flight within a reactor (or reaction chamber) asdescribed earlier to create electrically conductive interconnectedagglomerations of graphene sheets 303B, which may vary in shape, size,position, orientation, and/or structure. Such variances are influencedin differences in crystallinity and the particular type of carbonallotrope(s) used for creation of electrically conductive interconnectedagglomerations of graphene sheets 303B. “Crystallinity”, as generallyunderstood and as referred to herein, implies the degree of structuralorder in a solid. In a crystal, atoms or molecules are arranged in aregular, periodic manner. The degree of crystallinity therefore has asignificant influence on hardness, density, transparency, and diffusion.

Mesoporous carbon-based particle 100 can be produced in the form of anorganized scaffold, such as a carbon-based scaffold, out of a reactor(including thermal or microwave-based reactor) or be created (at leastpartially) during post-processing activities taking place outside ofprimary synthesis within a reactor.

Plasma processing and/or plasma-based processing, may be conductedwithin a reactor as disclosed in U.S. Pat. No. 9,767,992, where supplygas is used to generate a plasma in the plasma zone to convert a processinput material (such as methane and/or other suitable hydrocarbons in agaseous phase) into separated components in a reaction zone (such as areaction chamber) to facilitate in-flight synthesis of carbon-basedmaterials, including mesoporous carbon-based particle 300A grown tocreate carbon scaffold 300H at approximately 1 atmosphere.

Alternative to synthesis by or within a microwave reactor as describedabove, thermal energy may be directed toward or near carbon-containingfeedstock materials supplied in a gaseous phase onto sacrificialsubstrate 306B to sequentially deposit multiple layers of mesoporouscarbon-based particles 300A by, for example, plasma spray-torch system400B shown in FIG. 4B. Such particles may be either fused togetherin-flight (in a microwave reactor) or deposited (in a thermal reactor)in a controlled manner to achieve varying concentration levels ofcarbon-based particles 300A to therefore, in turn, achieve “graded”electrical conductivity proportionate to concentration levels ofmesoporous carbon-based particles 300A. Such procedures may be used toformulate porous carbon-based electrode structure (such as carbonscaffold 300H) that has a high degree of tunability (regardingelectrical conductivity and ionic transport) while also eliminating manyproduction steps and otherwise retaining a conventional outwardappearance.

An objective of producing mesoporous carbon-based particle 300A out of,for example, a microwave reactor, includes producing open porousscaffold 302A with an open cellular structure such that a liquid-phaseelectrolyte can easily infiltrate into the pores of mesoporouscarbon-based particle 300A via (at least) open porous scaffold 302A. Asgenerally understood and as referred to herein, a “porous medium” or a“porous material” refers to a material containing pores, also referredto herein as “voids”. Skeletal portions of open porous scaffold 302A maybe referred to as a “matrix” or a “frame”, and pores (such ashierarchical pores 303A and/or 307F) can be infiltrated with a fluid(liquid or gas), whereas skeletal material is usually formed as a solidmaterial.

Porosity of the Mesoporous Carbon-Based Particle-in Detail

A porous medium, such as mesoporous carbon-based particle 300A, can becharacterized by its porosity. Other properties of the medium (such aspermeability, tensile strength, electrical conductivity, and tortuosity)may be derived from the respective properties of its constituents (ofsolid matrix and fluid interspersed therein), as well as media porosityand pore structure. Mesoporous carbon-based particle 300A can be createdout of a reactor (and possibly also subsequently post-processed, to bediscussed in detail herein) to achieve desirable porosity levels thatare unexpectedly conducive for ion diffusion (such as Li ion), whereascontacting electrically conductive interconnected agglomerations ofgraphene sheets 303B facilitate electron conduction while also allowingfor electrons to reunite with positive ions at reaction sites.

Regarding, porosity and tortuosity of open porous scaffold 302A ofmesoporous carbon-based particle 300A, an analogy may be made to marblesin a glass jar. Porosity, in this example, refers to spacing between themarbles that allows liquid-phase electrolyte to penetrate into voidspaces between the marbles, similar to hierarchical pores 307F thatdefine ion diffusion pathways 309F. The marbles themselves may be likeSwiss cheese, by allowing electrolyte not only to penetrate in cracksbetween agglomerations of graphene sheets 303B, but also intoagglomerations of graphene sheets 303B themselves. In this example aswell as others, the relative “shortening” of ion diffusion pathways 309Frefers to how long it takes Li ions infiltrated therein by, for example,capillary action to contact active material (such as S confined withinpores 305F). Ion diffusion pathways 309F accommodate convenient andrapid infiltration and diffusion of electrolyte, which may contain Liions, into mesoporous carbon-based particle 300A, synthesized further tocreate carbon scaffold 300H with graded electric conductivity.

The “shortening” of ion diffusion pathways 309F refers toward theshortening of diffusion lengths through which Li ions move within openporous scaffold 302A in carbon scaffold 300H and not active materialitself (as it is commonly understood that the diffusion length of theactive material may be shortened only by making the thickness of theactive material lesser or smaller). Ion diffusion pathways 309F can actas ion buffer reservoirs by controlling flow and/or transport of ionstherein to provide a surprisingly favorable freer flowing structure forion transport therein, as may be beneficial for ion confinement andtransport during electrochemical cell charge-discharge cycles. Transportof Li ions throughout ion diffusion pathways 309F in the generaldirections shown in FIG. 1F can take place in a liquid electrolyteinitially infused and captured within open porous scaffold 302A, wheresuch infusion of electrolyte occurs prior to cyclic carbon scaffold 300Husage. Alternatively, examples exist permitting for the initialdiffusion and distribution of liquid-phase electrolyte in open porousscaffold 302A of mesoporous carbon-based particle 300A to fill up andoccupy hierarchical pores 303A and/or 307F prior to usage of carbonscaffold 300H, synthesized or otherwise created by layer-on-layerdeposition of mesoporous carbon-based particles 300A. In alternative oraddition to complete filling of open porous scaffold 302A withelectrolyte as described, vacuum or air may also be used to fillhierarchical pores 303A at least partially and/or 307F, which may allowor assist with wetting of electrolyte with carbon-containing exposedsurfaces within open porous scaffold 302A (to be described furtherherein).

Once an electrode is formed using carbon scaffold 300H, throughadditional exposure and electrochemical reactions, Li ions actuallybounce from one location to another by a chain reaction, similar to thestriking of “newton” balls, where one hits to result in forcetransference resulting in the movement of other balls. Similarly, eachLi ion moves a short distance, yet remains able to move great numbers ofLi ions in the collective through this type of chain reaction asdescribed. The extent of individual Li ion movement may be influenced bythe quantity of Li ions supplied altogether to carbon scaffold 300H viacapillary infusion into open porous scaffold 302A, as may be thecrystallographic arrangement of Li ions and/or particles in, around, orwithin agglomerations of graphene sheets 303B.

Electrochemical Cell Electrode (Anode or Cathode) Created from CarbonScaffold

Carbon scaffold 300H can be functionally integrated in a variety ofbattery or supercapacitor applications, battery types including Li ionbatteries and Li S batteries, as well as Li air cathodes, upon suitabledevelopment. Such an example battery system may include anelectrochemical cell configured to supply electric power to a system.The electrochemical cell may have an anode containing an anode activematerial, a cathode containing a cathode active material, a porousseparator disposed between the anode and the cathode, and an electrolytein ionic contact with the anode active material and the cathode activematerial.

The anode and cathode may include sacrificial substrate 306B (that iselectrically conductive), with a first layer deposited there-upon as afirst contiguous film having a first concentration of mesoporouscarbon-based particles 300A and/or 302H, each mesoporous carbon-basedparticle 300A and/or 302H contacting another and being composed ofelectrically conductive interconnected 3D aggregates of graphene sheets303B. Aggregates of graphene sheets 303B are sintered together to formopen porous scaffold 302A (shown in FIG. 3A) that facilitates electricalconduction along and across contact points of the graphene sheets 303B.Open porous scaffold 302A has a 3D hierarchical structure with mesoscalestructuring in combination with micron-scale fractal structuring, anyone or more further featuring minute carbon-based particles 304Hinterspersed in and/or between adjacent carbon-based particles 300Aand/or 302H.

A porous arrangement is formed in open porous scaffold 302A. The porousarrangement is conducive to receive electrolyte dispersed therein forion (such as Li ion) transport through interconnected hierarchical pores303A and/or 307F that define one or more channels including:

-   -   (1) microporous frameworks defined by a dimension 303F of >50 nm        that provide tuneable Li ion conduits;    -   (2) mesoporous channels defined by a dimension 303F of about 20        nm to about 50 nm (defined under IUPAC nomenclature and referred        to as “mesopores” or “mesoporous”) that act as Li ion-highways        for rapid Li ion transport therein; and    -   (3) microporous textures defined by a dimension 103F of <4 nm        for charge accommodation and/or active material confinement.

The first layer including a first electrical conductivity ranging from500 S/m to 20,000 S/m. A second layer is deposited on the first layer.The second layer has a second contiguous film with a secondconcentration of mesoporous carbon-based particles 300A in contact witheach other to yield a second electrical conductivity ranging from 0 S/mto 500 S/m (lower than the first electrical conductivity).

FIG. 3G shows a micrograph of an example enlarged section of the 3Dself-assembled binder-less mesoporous carbon-based particle shown in anyone or more of the presently disclosed implementations including bothmacropores 301G and micropores 302G.

FIG. 3H shows an illustrative schematic representation of amulti-layered carbon-based scaffolded structure, each layer comprisingvarious concentrations of the 3D mesoporous carbon-based particles shownin FIGS. 3A-F, deposited on an electrically conductive substrate.

Carbon scaffold 300H may be pre-lithiated and later infused with Li ionliquid solution via capillary action to create lithiated carbon scaffold400A (to be further explained herein) as shown in FIG. 4A. Interimlayers 406A, 408A, 410A, and 412A (having defined thicknesses in thevertical direction extending from the current collector, which may be asacrificial and/or electrically conductive substrate, toward electrolytelayer 414A) may be synthesized in-flight in a microwave reactor, ordeposited layer-by-layer in or out of a thermal reactor. Interim layers406A, 408A, 410A, and 412A have varying electrical conductivity rangingfrom high (such as at interim layer 406A) to low (such as at layer 412A)in a direction orthogonal and away from the current collector, which mayalso be a sacrificial and/or electrically conductive substrate. Varyingelectrical conductivity may be at least partially proportionate tointerfacial surface tension of a Li ion solution infiltrated into theporous arrangement of the open porous scaffold, where infiltration ofthe Li ion solution is done via capillary infusion engineered to promotewetting (to be further explained herein) of surfaces of open porousscaffold 302A exposed to Li ion solution, as well as the prevalence(concentration) of conductive carbon particles 404A interspersed withinmesoporous carbon-based particles 402A (that are equivalent or similarto mesoporous carbon-based particles 300A, 300E and/or the like).

Li ion diffusion pathways 309F (as shown in FIG. 1F) ensure thatdeposition and stripping operations associated with one or moreoxidation-reduction (“redox”) reactions occurring within mesoporouscarbon-based particles 300A and/or 302H are uniform. Also, anode activematerial and/or cathode active material resides in pores of the anodeand the cathode, respectively, and may contain single-layer graphene(SLG) and/or few-layer graphene (FLG) including from 1 to 10 grapheneplanes, respectively, the graphene planes being positioned in an alignedorientation along a vertical axis. Anode active material or cathodeactive material may have a specific surface area from approximately 500m²/g to 2,675 m²/g when measured in a dried state, and may contain agraphene material comprising any one or more of pre-lithiated graphenesheets, pristine graphene, graphene oxide, reduced graphene oxide,graphene fluoride, graphene chloride, graphene bromide, graphene iodide,hydrogenated graphene, nitrogenated graphene, boron-doped graphene,nitrogen doped graphene, chemically functionalized graphene, physicallyor chemically activated or etched versions thereof, conductive polymercoated or grafted versions thereof, and/or combinations thereof.

In any one or more of the discussed examples in relation to lithiatedcarbon scaffold 400A, electrically conductive interconnectedagglomerations of graphene sheets 303B are sintered together to formopen porous scaffold independent of a binder, however alternativeexamples do exist where a binder is used. Configurations with or withouta binder may each involve open porous scaffold 302A acting or serving asan active lithium intercalating structure with a specific capacity of744-1,116 mAh/g, or more. Also, examples include the preparation ofelectrically conductive interconnected agglomerations of graphene sheets303B using chemically functionalized graphene, involving the surfacefunctionalization thereof, comprising imparting to open porous scaffold302A a functional group selected from quinone, hydroquinone, quaternizedaromatic amines, mercaptan, disulfide, sulfonate (—SO₃), transitionmetal oxide, transition metal sulfide, other like compounds or acombination thereof.

The current collector shown in FIG. 4A, is, for example, at leastpartially foam-based or foam-derived and is can be selected from any oneor more of metal foam, metal web, metal screen, perforated metal,sheet-based 3D structure, metal fiber mat, metal nanowire mat,conductive polymer nanofiber mat, conductive polymer foam, conductivepolymer-coated fiber foam, carbon foam, graphite foam, carbon aerogel,carbon xerogel, graphene foam, graphene oxide foam, reduced grapheneoxide foam, carbon fiber foam, graphite fiber foam, exfoliated graphitefoam, and combinations thereof.

Anode or cathode electrically conductive or insulative material,referred to herein as “active material” can include any one or more ofnanodiscs, nanoplatelets, nano-fullerenes, carbon nano-onions (CNOs),nano-coating, or nanosheets of an inorganic material selected from: (i)bismuth selenide or bismuth telluride, (ii) transition metaldichalcogenide or trichalcogenide, (iii) sulfide, selenide, or tellurideof a transition metal; (iv) boron nitride, or (v) a combination thereof.The nanodiscs, nanoplatelets, nano-coating, or nano sheets can have athickness less than 100 nm. In similar or dissimilar examples, thenanoplatelets can have a thickness less than 10 nm and/or a length,width, or diameter less than 5 μm.

Processes for Producing an Electrochemical Cell Electrode (Anode orCathode) Created from Carbon Scaffold-Generally

Example processes for producing a three-dimensional (3D) mesoporouselectrode, such as that created from lithiated carbon scaffold 400A, caninclude depositing (such as from one or more plasma-based thermalreactors or torches, in which thermal energy is propagated through aplasma and/or feedstock material supplied in a gaseous state) mesoporouscarbon-based particles 300A or 400A to form a first contiguous filmlayer (such as layer 406A shown in FIG. 4A) on a substrate, where thefirst contiguous film layer is characterized by a first electricalconductivity. Each of the mesoporous carbon-based particles compriseselectrically conductive three-dimensional (3D) aggregates oragglomerations of graphene sheets 303B. The aggregates are sinteredtogether to form open porous scaffold 302A that facilitates electricalconduction along and across contact points of the graphene sheets. Aporous arrangement formed in open porous scaffold 302A, where the porousarrangement is conducive to receive electrolyte dispersed therein for Liion transport through interconnected pores (such as hierarchical pores303A and/or 307F) that define one or more Li ion diffusion pathways309F. The first contiguous film layer has an average thickness nogreater than 100-200 μm. In an example, a binder material is combinedwith graphene sheets 303B to retain graphene sheets 303B in a desiredposition to impart structure to open porous scaffold 302A. The bindermay be or comprise a thermosetting resin or a polymerizable monomer,wherein curing the resin or polymerizing the polymerizable monomer formsa solid resin or polymer with assistance of heat, radiation, aninitiator, a catalyst, or a combination thereof. The binder may beinitially a polymer, coal tar pitch, petroleum pitch, mesa-phase pitch,or organic precursor material and is later thermally converted into acarbon material.

Additional quantities of mesoporous carbon-based particles 303A and/or400A are deposited on the first contiguous film layer to form a secondcontiguous film layer there-upon, the second contiguous film layerhaving a second electrical conductivity lower than the first electricalconductivity, and being positioned closer to electrolyte 414A and awayfrom the current collector (which may be a sacrificial substrate).

Li ion solution can be infiltrated into (such as by capillary infusionaction) open porous scaffold 302A react with exposed carbon on surfacesthereof to facilitate Li ion dissociation and electric current supply,where the exposed carbon on the open porous scaffold including a surfacearea greater than approximately 100 m²/gm.

Processes for Producing an Electrochemical Cell Electrode (Anode orCathode) Created from the Carbon Scaffold-In Detail

Mesoporous carbon-based particles 300A and/or lithiated carbon scaffold400A can be synthesized ‘in-flight’ in a microwave reactor, or depositedin a bottom-up manner, referring to a layer-by-layer deposition or“growth” within a thermal reactor, and may then be cast, via a liquidslurry to be subsequently dried to form a carbon-based electrode thatmay be suitable for implementation or incorporation within a Li ionbattery. Such a slurry may, in some examples, comprise chemical bindersand conducting graphite, along with the electrochemically active innatecarbon.

The term “hierarchical”, as generally understood in an engineeringcontext and as used herein, refers to an arrangement of items in whichthe items are represented as being above, below, or at the same level asone another. Here, mesoporous carbon-based particle 300A and/orlithiated carbon scaffold 400A may be grown by layer-by-layer depositionin a thermal reactor to create one or more “grades” (as indicated bylayers 406A to 412A of mesoporous conductive particles 300A, 302H and/or402A), referring to that created by specific control of electrical(referring to contact points of electrically conductive interconnectedagglomerations of graphene sheets 303B) and ionic (referring to Li iondiffusion pathways 309F) conducting gradients throughout the thicknessof lithiated carbon scaffold 400A. Tuning of each individually depositedlayer 406A through 412A results in relatively higher electricalconductivity at the current collector interface, and progressive lowerelectrical conductivity moving outwardly therefrom.

Electrically conductive interconnected agglomerations of graphene sheets303B within mesoporous carbon-based particle 300A serve as bothelectrical conductors, by conducting electric current through contactpoints and/or regions, and as “active” Li intercalating structures, andtherefore may be configured to provide a source for the specificcapacity of the anode electrode at 744-1,116 mAh/g, such as 2-3 timesthat otherwise available from conventional graphite anodes at 372 mAh/g.As a result, interconnected 3D bundles of graphene sheets 102 withinmesoporous carbon-based particle 100 may be considered as ‘nanoscale’electrodes that concurrently enable a relatively high-volume fraction ofelectrolytically active material along with efficient, 3Dinterpenetrating, ion and electron pathways.

This unique 3D structure of mesoporous carbon-based particle 100 enablesboth storage of electric charge at its exposed surfaces (via capacitivecharge storage) for desirable high-power delivery, relative toconventional applications, and also provides faradaic redox ions withinthe bulk thereof for desirable high electric energy storage. “Redox”, asgenerally understood and as referred to herein, refers to“reduction-oxidation” reactions in which the oxidation states of atomsare changed involving the transfer of electrons between chemicalspecies, most often with one species undergoing oxidation while anotherspecies undergoes reduction.

“Faradaic”, as generally understood and as referred to herein, refers toa heterogeneous charge-transfer reaction occurring at the surface of anelectrode, prepared with, and/or otherwise incorporating mesoporouscarbon-based particle 300A. For instance, pseudocapacitors storeelectrical energy faradaically by electron charge transfer betweenelectrode and electrolyte. This is accomplished through electrosorption,reduction-oxidation reactions (redox reactions), and intercalationprocesses, termed pseudocapacitance.

Roll-to-Roll Processing for Producing an Electrochemical Cell Electrode(Anode or Cathode) Created from the Carbon Scaffold

Regarding manufacturing, lithiated carbon scaffold 400A can bemanufactured (to fabricate and/or build electrochemical cell electrodes,such as cathodes and/or anodes) in large-scale quantities by sequential,layer-by-layer (such as layers 406A through 412A shown in FIG. 4A)deposition of concentrations of mesoporous carbon-based particle 300Aand/or 300E onto a moving substrate (such as a current collector)through a roll-to-roll (“R2R”) production approach. By consolidating 3Dcarbon scaffold structures directly out microwave reactors (analogous toexiting plasma spray processes), electrode films can be continuouslyproduced without the need for toxic solvents and binders that areotherwise used in slurry cast processes for battery electrodes.Therefore, battery electrodes employing lithiated carbon scaffold 400Amay be more readily produced with controlled electrical, ionic, andchemical concentration gradients due to the “layer-by-layer”, sequentialparticle deposition capabilities of a plasma-spray type processes; andspecific elements (such as dopants) can also be introduced at differentstages within the plasma deposition process.

Also, due to the pores 303A and/or 307F interspersed throughoutmesoporous carbon-based particle 100, lithiated carbon scaffold 400A maybe manufactured in a manner such that it is gravimetrically, referringto a set of methods used in analytical chemistry for the quantitativedetermination of an analyte based on its mass, superior to knowndevices. That is, mesoporous carbon-based particle 300A, with poresand/or voids defined throughout 3D bundles of graphene sheets 102 and/orconductive carbon particles 104, may be lighter than comparable batteryelectrodes without a mesoporous structure including various pores and/orvoids, etc.

Mesoporous carbon-based particle 100 may feature a ratio of activematerial to inactive material that is superior relative to conventionaltechnologies, in that greater quantities of active material areavailable and prepared for electricity conduction there-through relativeto inactive and/or structural reinforcement material. Such structuralreinforcement material, although involved in defining a generalstructure of mesoporous carbon-based particle 300A, may not be involvedor as involved in electrically conductive interconnected agglomerationsof graphene sheets 303B. Accordingly, due to its high active material toinactive material ratio, mesoporous carbon-based particle 300A maydemonstrate superior electrical conductivity properties relative toconventional batteries, as well as being significantly lighter than suchconventional batteries given that carbon may be used to replacetraditionally used heavier metals. Therefore, mesoporous carbon-basedparticle 300A may be particular well-suited for demanding end-useapplication areas that also may benefit from its light weight includeautomobiles, light trucks, etc.

Mesoporous carbon-based particle 300A may be created to relyelectrically conductive interconnected agglomerations of graphene sheets303B to obtain a percolation threshold, referring to a mathematicalconcept in percolation theory that describes the formation of long-rangeconnectivity in random systems. Below the threshold a giant connectedcomponent does not exist, while above it, there exists a giant componentof the order of system size. Accordingly, 3D bundles of grapheneelectrically conductive interconnected agglomerations of graphene sheets303B may conduct electricity from the current collector, as shown inFIG. 4A, toward electrolyte 414A.

Roll-to-Roll (“R2R”) Plasma Spray Torch Deposition System

As a variation from the existing atmospheric MW plasma reactor withparticle-based output, integrated, contiguous 3D hierarchical carbonscaffold films (composed of multiple mesoporous carbon-based particles300A and/or the like agglomerated together and/or contacting to formcontiguous layers, films, and/or sheets) can be constructed utilizing aspray torch configuration, such as that shown by roll-to-roll (“R2R”)system 400 b. Plasma torches (generally) permit for materials to beinitially formulated, similar to waveguided reactor, then acceleratedinto an impact zone on a substrate surface (moving or stationary)wherein each zone can provide for unique control of dissimilar (mixedphase or composite) material synthesis, formulation (consolidation), andintegration (densification).

The plasma torch in combination with a continuous, moving substrateenable a unique additive type of process control (such as both withinthe hot plasma and beyond the plasma afterglow region up to the impactzone of the substrate) of properties, such as defect density, residualstress, through thickness chemical and thermal gradients, phasetransformations, and anisotropy. For the case of battery electrodefabrication, not only can the atmospheric MW plasma torch createformulated and integrated continuous 3D hierarchical mesoporous graphenefilms without the need for toxic solvents such as NMP and or use ofbinders and conductive carbons (at the very least reduction) inaccordance with the slurry casting process, but the plasma torch can beused to create integrated electrode/current collector film structuresfor enhanced performance at a reduced cost.

FIG. 4B shows in detail roll-to-roll (“R2R”) system 400 b employing anexample arrangement of a group 444B of plasma spray torches 422B through428B (such as 422B, 424B, 426B, and/or 428B) configured to performlayer-by-layer deposition to fabricate, otherwise referred to as“growing”, carbon-based scaffold 300H, shown in FIG. 3B, and/or variantsthereof, incrementally. Group 444B of plasma spray torches 414B through420B are oriented in a continuous sequence above the R2R processingapparatus 440B, which, may include wheels and/or rollers 434B and 439Bconfigured to rotate in the same direction, 430B and 432B, respectively,to result in translated forward motion 436B of sacrificial layer 402Bupon which layers 442B of carbon scaffold 436B may be deposited in alayer-by-layer manner to achieve a “graded” electrical conductiongradient proportionate to the concentration level of mesoporouscarbon-based particles 300A contained per unit volume area in eachprogressive deposited layer (such as interim layers 406A-412A).

Such deposition may involve the positioning of group 444B of plasmaspray torches 414B through 420B as shown in FIG. 4B, with an initial, indirection of forward motion 436B, spray torch 414B extending thefurthest in a downward direction, toward sacrificial layer 404B fromfeedstock supply line 412B, positioned to spray 422B carbon-basedmaterial to deposit initial layer 404B (also may be shown as interimlayer 406A in FIG. 4A, and so on and so forth) of carbon scaffold 300Hon sacrificial layer 402B. Initial layer 404B may be deposited toachieve the highest conductivity values, with each of the subsequentlayers 406B through 410B featuring a proportionately less-densedispersion of mesoporous carbon-based particle 300A composingcarbon-based scaffold 300H to achieve a ‘graded’ electric gradient forlayers 442B.

That is, plasma spray torches 414B through 420B may be oriented to haveincrementally decreasing (or otherwise varying) heights as shown in FIG.4B, such that each spray torch from group 444B may be tuned to spray,from spray 422B to 428B, respectively, sprays of carbon-based feedstockmaterial supplied by feedstock supply line 412B. Accordingly, batteryelectrodes can be more readily produced with controlled electrical,ionic, and chemical concentration gradients due to the “layer-by-layer”,sequential deposition described herein with connection to plasmaspray-torch system 400B, which presents desirable features of plasmaspray type processes; and, specific elements or additional ingredientscan also be introduced at different stages within the plasma-based spraydeposition process described by plasma spray-torch system 400B. Suchcontrol may, extend to tunability of plasma spray-torch system 400B toachieve target electric field and/or electromagnetic field properties ofany one or more of layers 442B.

Group 444B of plasma spray torches 414B through 420B may employplasma-based thermally enhanced carbon spraying techniques to providecarbon coating processes in which melted (or heated) materials aresprayed onto a surface. The “feedstock” (coating precursor) is heated byelectrical (plasma or arc) or chemical means (combustion flame).

Thermal spraying by plasma spray torches 414B through 420B can providethick coatings (approx. thickness range is 20 μm or more to several mm,depending on the process and feedstock), over a large area at highdeposition rate as compared to other coating processes such aselectroplating, physical and chemical vapor deposition. Coatingmaterials available for thermal spraying include metals, alloys,ceramics, plastics, and composites. They are fed in powder or wire form,heated to a molten or semi-molten state, and accelerated towardssubstrates in the form of μm—size particles. Combustion or electricalarc discharge is usually used as the source of energy for thermalspraying. Resulting coatings are made by the accumulation of numeroussprayed particles. The surface may not heat up significantly, allowingthe coating of flammable substances.

Coating quality is usually assessed by measuring its porosity, oxidecontent, macro and microhardness, bond strength and surface roughness.The coating quality increases with increasing particle velocities.

Carbon Scaffold Implemented in a Li S Secondary Battery

Group 444B of plasma spray torches 414B through 420B may be configuredor tuned to spray carbon-based material in a controlled manner toachieve specific desired hierarchical and organized structures, such asopen porous scaffold 302A of mesoporous carbon-based particle 300Aand/or 300E with hierarchical pores 307F suitable to be used for Li ioninfiltration via capillary action therein dependant on percentageporosity of mesoporous carbon-based particle 300A and/or 300E. Totalquantities of S able to be infused into hierarchical pores 307F and/ordeposited on exposed surface regions of mesoporous carbon-based particle300A and/or 300E (and other such similar structures) may depend on thepercentage porosity thereof as well, where 3D fractal-shaped structuresproviding larger pores, such as pores 305F, each having dimension 103Fcan efficiently accommodate and micro-confine S for desired time-framesduring electrochemical cell operation. Examples exist permitting for thecombination of S to prevent any resultant polysulfides (PS) migratingout of pores 305F purely by designing and growing structural S, withconfinement of S being targeted at a defined percentage, such as: 0-5%,0-10%, 0-30%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, and/or 0-100%,any one or more of such ranges successfully showing of retardation ofpolysulfide migration out of the electrode structure.

Carbon Scaffold Implemented in a Li Air Secondary Battery

Existent Li air cathodes may last only 3-10 cycles, and thus have notyet been universally understood to provide very promising or reliabletechnologies. In such cathodes, air itself acts as the cathode,therefore the reliable and robust supply of air flowing through thecathode, such as through pores, orifices, or other openings, effectivelycurrently precludes realistic applications in consumer grade portableelectronic devices such as smartphones.

Devices can be made with some sort of air pump mechanism, but airpurification remains an issue, given that any amount of impurityprevalent in the air can and will react with available Li in parasiticside-reactions degrading specific capacity of the overallelectrochemical cell. Moreover, air only provides only about 20.9% O₂,and thus is not as efficient as other alternative current advancedbattery technologies.

Nevertheless, even in view of the above-mentioned challenges, examplesprovided above relating to mesoporous carbon-based particle 300A, 300Eand/or any variants thereof implemented in carbon scaffold 300H and/orlithiated carbon scaffold 400A can be configured to function in a3D—printed battery. Notably, measures can be taken to guard against,such as by tuning to achieve desirable structural reinforcement incertain targeted areas of open porous scaffold 302A, to prevent againstunwanted and/or sudden collapse of porous structures, such as to create‘clogging’ of passageways defined therein. In example, carbon scaffold300H can be decorated with a myriad of metal oxides to achieve suchreinforcement, which may also control or otherwise positive contributeto mechanical tunnelling of the structure itself once lithium reactswith air to spontaneously form a solid from that state, etc. Traditionalcircumstances (such as absent special preparations undertaken regardingimplementation of the disclosed mesoporous carbon-based particle 300Aand/or the like with Li air cathodes) can otherwise involve Li ionsreacting with carbon provided in a gaseous state, such that the Li ionand the carbon-containing gas react to form a solid that expands. And,depending on where this expansion occurs, can mechanically degrade theoverall carbon-based mesoporous scaffold structure, such as of carbonscaffold 300H.

Pre-Lithiation of 3D Mesoporous Carbon-Based Particle as a “Host”

To enable alternative non-lithium or lithiated carbon-based scaffoldedcathodes, such as those confining sulfur, oxygen, and vanadium oxide,over current lithium oxide compound cathodes, as well as to accommodatefirst charge lithium loss (resulting reduced coulombic efficiency) incurrent lithium-ion cells, a scalable pre-lithiation method forcarbon-based structured intended for implementation in electrochemicalcell electrodes may be required. As a result, various experimentalattempts have been conducted with mesoporous carbon-based particle300A,300E and/or any derivative structures based therefrom, includingcarbon scaffold 300H such as ball milling, post thermal annealing, andelectrochemical reduction from an additional electrode. Such effortshave been used to “pre-lithiate”, referring to chemically preparing acarbon-based structure to react with and/or confine lithium physicallyand/or chemically, but have met with uniformity, lithium reactivity,costs, and scalability challenges.

Nevertheless, by fine-tuning reactor process parameters, 3D mesoporouscarbon-based particle 300A, 300E, and/or carbon scaffold 300H may besynthesized and/or fabricated by layer-by-layer deposition process, assubstantially discussed earlier, to serve as a carbon-based ‘host’structure with engineered surface chemistry (such as including nitrogenand oxygen doping) to facilitate rapid decomposition (involvingdisproportionation of oxides).

Upon thermal (referred to herein as “spark”) activation, Li metal can bespontaneously (such as without a pressure gradient) and non-reactivelyinfiltrated (driven by capillary forces) to create a controlled,pre-lithiated carbon structure (or particle building blocks).Subsequently, such “pre-lithiated” particle building blocks can besynthesized into an integrated composite film with graded electricalconductivity from:

-   -   (1) a high conductivity at a back plane in contact with the        current collector (such as shown by interim layer 406A, to    -   (2) an insulated ion conducting layer at the        electrolyte/electrode plane.

Surface chemistry, as may be related to non-reactive infiltration of Limetal can be tuned by optimizing oxide thermal reduction degree(exotherm) by using thermogravimetric analysis (TGA) or differentialscanning calorimetry DSC analytical techniques.

To address scalability concerns as may be related to transitioning froma low-volume laboratory testing and sample production environment, to ahigh-volume large-scale plant capable of fulfilling multiple customerorders simultaneously, the above described “pre-lithiation” process isreadily adaptable to a continuous roll-to-roll (R2R) format, analogousto other liquid melt wetting processes such as brazing.

Thin film lithium clad foil (tantalum or copper) can be loaded onto aheated calendaring roll, to be brought into contact with 3D mesoporouscarbon-based particle 300A and/or the like pre-form (or carbon film, inthe case of the spray torch process) in a controlled thermal, dryenvironment. Thermal residence (soak) time, gradient, and appliedpressure can adjusted and controlled to facilitate both: (1) “spark”activation; and (2) infiltration process steps.

“Spark” Lithiation of the Carbon Scaffold

-   -   Historically, prior to the development of Li metal infusion        methods into carbon-based structures and/or agglomerate        particles, efforts were undertaken to assess the following two        scenarios:

(1) growing microwave graphene sheets that have extended de-spacing thatwould allow intercalation to occur in-between individual graphene sheetsat a much more efficient or a faster rate than what would occur intypical, commercially-available, graphene sheets; and, growing FLG insuch a way to successfully and repeatably achieve such higherde-spacing; and

-   -   (2) using a wet liquid Li metal front that propagates into        hierarchical pores 303A and/or 307F defined by open porous        scaffold 302A of 3D mesoporous carbon-based particle 300A and/or        300E. Attraction from Li metal to exposed carbon-based surfaces        wet the same in an efficient way relative to otherwise        performing functionalization on exposed carbon-based surfaces.

Presently disclosed examples relating to thermal reactors furtherprovide for capabilities for post processing to create highly organizedand structured carbons that have that particular functioning relating tothe infiltration of metal and/or other species, such as infiltration ofaluminium into a silicon carbide-sintered material, and hammering thesurface of the particles to promote infiltration of a molten (Li) metalfront without additional pressure from outside sources. Such effortspermit for continuous wetting instead of using pressure to push metalinto open porous scaffold 302A of 3D mesoporous carbon-based particle300A and/or 300E.

FIG. 4A shows a schematic representation of agglomerations oraggregations of 3D mesoporous carbon-based particles 402A, akin to 3Dmesoporous carbon-based particles 300A and/or 300E, synthesized ordeposited at varying concentration levels in layers 406A to 412A, frommost concentrated to least concentrated. All layers 406A through 412A,subsequent to creation, can be infiltrated, via non-reactive capillaryinfusion methods, with Li metal and/or Li ion solution in liquid stateor phase for intercalation of Li ions in-between individual graphenesheets of electrically conductive interconnected agglomerations ofgraphene sheets 303B of 3D mesoporous carbon-based particle 300A, whichmay be created with a spacing of 1 to 3 Å to accommodate more Li ionsbetween alternating graphene sheets when compared to conventionalcommercially available graphene sheet stacks.

Voids (referring to vacant regions or spaces) between adjacent and/orcontacting mesoporous carbon-based particles 300A and/or 300E composingany one or more of layers 406A-412A of lithiated carbon scaffold 400Amay be encased or at least partially covered by, at a section oflithiated carbon scaffold 400A positioned away from the currentcollector and facing the electrolyte, a passivation layer. Such apassivation layer refers a material becoming “passive,” that is, lessaffected or corroded by the environment of future use. In addition, orin the alternative, an ion conduction (insulating) or graded interphaselayer can be deposited on layer 412A facing electrolyte 414A to minimizeside reactions with free and/or unattached (physically and/orchemically) Li in ionic form. Prior to the deposition or placement ofany such encasing layer, lithium, in the form of Li ions, may be flowedin liquid state into hierarchical pores 303A and/or 307F of open porousscaffold 302A of any one or more of mesoporous carbon-based particles300A and/or 300E composing layers to form electrochemical gradientsproportionate to the level of concentration of mesoporous carbon-basedparticles 300A and/or 300E composing each layer of layers 406A-412A,layer 406A having the highest concentration of mesoporous carbon-basedparticles 300A and/or 300E permitting for relatively high levels ofelectric current conduction between electrically conductiveinterconnected agglomerations of graphene sheets 303B. Layers 408A-412A(and additional such layers, if necessary or desirable) each haveprogressively lower (sparser) concentration levels of mesoporouscarbon-based particles 300A and/or 300E, thus correspondingly havingproportionately lower levels of electric conductance capabilities.

Repeated (cyclical) li ion electrode usage in secondary batteries canresult in problems due to metal formation, such as volume expansionduring re-depositing in electroplating operations (referring to aprocess that uses an electric current to reduce dissolved metal cationsso that they form a thin coherent metal coating on an electrode). Theterm can also be used for electrical oxidation of anions on to a solidsubstrate, as in the formation of silver chloride on silver wire to makesilver/silver-chloride electrodes. Electroplating is often used tochange the surface properties of an object (such as abrasion and wearresistance, corrosion protection, lubricity, aesthetic qualities), butmay also be used to build up thickness on undersized parts or to formobjects by electroforming.

Processes used in electroplating with relation to infiltration of Li ionsolution into lithiated carbon scaffold 400A may be referred to aselectrodeposition (also known as electrophoretic deposition (EPD)) andis analogous to a concentration cell acting in reverse. Electrophoreticdeposition (EPD) is a term for a broad range of industrial processeswhich includes electrocoating, cathodic electrodeposition, anodicelectrodeposition, and electrophoretic coating, or electrophoreticpainting. A characteristic feature of this process is that colloidalparticles suspended in a liquid medium migrate under the influence of anelectric field (electrophoresis) and are deposited onto an electrode.All colloidal particles that can be used to form stable suspensions andthat can carry a charge can be used in electrophoretic deposition. Thisincludes materials such as polymers, pigments, dyes, ceramics, andmetals.

Electroplating, as described above, with Li ions may result in a volumeexpansion as significant as approximately 400% or more of lithiatedcarbon scaffold 400A. Such an expansion is undesirable from a stabilitystandpoint micro-mechanically and causes degradation with many “deadzones”, referring to inactive or non-chemically and/or electricallyactivated regions, therefore ultimately preventing the derivation oflonger lifespans out of so-equipped Li ion batteries. In any case, it isdesirable to have a majority of the Li ion material plate, meaningreduce onto a smooth and uniform surface to therefore facilitate uniformdeposition of Li ions. Removal will also be smooth in a smooth planarinterface.

Layers 406A-412A, experimentally, have been found (in an example) tohave interfacial surface tension, γ_(sl), engineered to promote wettingof exposed carbon-based surfaces with Li ion. In an example, layer 406Amay be defined as having low-ion transport, high electricalconductivity, low electrical resistance (<1,000Ω); whereas layer 412(facing electrolyte 414A) may be defined as having high-ion transport,low electrical conductivity, and high electrical resistance(>1,000-10,000Ω).

In practice, Li, (when infiltrated into lithiated carbon scaffold 400A)may tend to form unwanted dendrites, defined as crystals that developwith a typical multi-branching tree-like form. Dendritic crystal growthmay be, in certain circumstances, illustrated (in example) by snowflakeformation and frost patterns on a window. Dendritic crystallizationforms a natural fractal pattern. Functionally, dendritic crystals cangrow into a supercooled pure liquid or form from growth instabilitiesthat occur when the growth rate is limited by the rate of diffusion ofsolute atoms to the interface. In the latter case, there must be aconcentration gradient from the supersaturated value in the solution tothe concentration in equilibrium with the crystal at the surface. Anyprotuberance that develops is accompanied by a steeper concentrationgradient at its tip. This increases the diffusion rate to the tip. Inopposition to this is the action of the surface tension tending toflatten the protuberance and setting up a flux of solute atoms from theprotuberance out to the sides. However, overall, the protuberancebecomes amplified. This process occurs again and again until a dendriteis produced.

Such Li ion dendrites (also in the form of acicular Li ion dendrites,“acicular” describing a crystal habit composed of slender, needle-likecrystal deposits) grow away from surfaces upon which Li ions areinfiltrated (such as upon and/or in-between individual graphene sheets303B). In some circumstances, with enough battery charge-dischargecycling, a dendritic protrusion or protuberance will grow across all theway through the cathode and “short” it out, describing when there is alow resistance connection between two conductors that are supplyingelectrical power to a circuit. This may generate an excess of voltagestreaming and cause excessive flow of current in the power source. Theelectricity will flow through a “short” route and cause a “short”circuit.

Employing any one or more of the advanced capillary Li ion infusiontechniques (to be described in further detail herein) into lithiatedcarbon scaffold 400A addresses many of the described shortcomings,inclusive of traditional Li ion battery cathode specific capacity. Anissue encountered in Li ion batteries is that the cathode provides onlya limited quantity of specific capacity or energy capability; moreover,on the anode side, decreases have also been observed in specificcapacity and energy density as well. Thus, even in view of howrelatively desirable (in terms of electric energy storage capacity andcurrent delivery) a Li ion battery may be compared to Li metal hydrideor lead-acid, or Ni Cad batteries (providing energy storage densityfigures a factor of 2-3 greater than any one of those traditionalbattery chemistries), even greater advancements in electric powerstorage and delivery are possible, regarding the protection against orprevention of unwanted Li-based dendritic formations, upon theincorporation of carbon-based materials, such as that disclosed by thepresent examples, and approaches theoretic capacities (not attained inpractice), of pure Li metal, which has a specific capacity of around3,800 mAh/g.

Other approaches have been undertaken including the development ofsolid-state batteries, describing no liquid phases at all. However,attention has returned to Li metal, due to oxide electrolyte being usedto achieve and stabilize contact with Li. And alternatives to Li metalhave also been explored including Si, Sn, and various other alloys.However, even upon elimination of Li metal, a Li ion source may still berequired (as originated from an opposing side of the battery device.)

Alternative-to-lithium materials in a Li ion battery electrode structuremay yield the following energy density values: oxides provide 260 mAh/g;and, sulfur provides 650 mAh/g. Due to its relatively high energydensity capabilities, it is desirable in battery electrode applicationsto confine sulfur (S), so it is not solubilized or dissolved intosurrounding electrolyte. To that effect, sulfur micro-confinement isneeded (as described earlier in relation to pores 305F of open porousscaffold 302A), describing that a “confined” (or “micro-confined”)liquid is a liquid that is subject to geometric constraints on ananoscopic scale so that most molecules are close enough to an interfaceto sense some difference from standard bulk conditions. Typical examplesare liquids in porous media or liquids in solvation shells.

Confinement (and/or micro-confinement, referring to confinement withinmicroscopic-sized regions) regularly prevents crystallization, whichenables liquids to be supercooled below their homogenous nucleationtemperature (even if this is impossible in the bulk state). This holdsin particular for water, which is by far the most studied confinedliquid.

Thus, in view of the various challenges presented above, and others notdiscussed here, various improvements to traditional graphite-basedanodes may be achieved by instead employing few layer graphene (FLG)materials and/or structures, defined as having less than 15 layers ofgraphene grown, deposited or otherwise organized in a stackedarchitecture with Li ions intercalated there-between at defined intervaland/or concentration levels. Any one or more of mesoporous carbon-basedparticle 300A, 300E and/or the like may be so prepared.

Doing so (going from graphite to FLG) may improve specific capacity fromapproximately 380 to over a 1,000 mAh/g for Li—intercalated carbon-basedstructures. Disclosed materials can replace graphite with FLG to permitfor a higher active surface area and can increase spacing in-betweenindividual graphene layers for infiltration of up to 2-3 Li ions, asopposed to just 1 Li ion as commonly may be found elsewhere.

In graphene, hexagonal carbon structures in each graphene sheet may staypositioned on top of each other—this is referred to as an “A-A” packingsequence instead of an “A-B” packing sequence. Particularly,configurations are envisioned for graphene sheets and/or FLG whereindividual layers of graphene may be stacked directly on top of eachother, to obtain incommensurate, disproportionate and/or otherwiseirregular, stacking, which in turn permits for the intercalation ofaddition Li ions in-between each graphene layer of FLG structures.

Under traditional conditions and circumstances, the insertion of Li ionsfrom, the top-down or bottom-up in layered graphene structures may proveexceedingly difficult in practice. Comparably, Li ions more easilyinsert in-between individual graphene layers (separated by a definabledistance). Thus, the key is to manage and tune exactly how much edgearea is available. In that regard, any of the carbon-based structureddisclosed herein are so tuneable. And carbon in graphene is alsoconductive-therefore, this feature provides for dual-roles by: (1)providing structural definition to FLG scaffold electrode structures(such as carbon scaffold 300H and/or lithiated carbon scaffold 400A);(2) and conductive pathways therein.

Production techniques employed to fabricate any one or more of thecarbon-based structures disclosed herein may indicate a desirability ofadjustment of individual graphene-layer edge lengths relative to planarsurfaces thereof; also, the adjustment of the spacing in betweenindividual graphene stacks may be possible. Graphene, given itstwo-dimensional structure, necessarily provides significantly moresurface area in which Li ions can be inserted. Thus, applying graphenesheets in accordance with various aspects of the subject matterdisclosed herein may provide a natural evolution in the direction ofenhanced energy storage density.

Individual graphene sheets are held in position as a part of the plasmagrowth process. Carbon based “gumball-like” structures areself-assembled in-flight (as described earlier) from FLG and/orcombinations of to form particles (such as mesoporous carbon-basedparticle 300A and/or the like) somewhat but with a defined long-rangeorder defined generally and herein as where solid is crystalline if ithas long-range order-once the positions of an atom and its neighbors areknown at one point, the place of each atom is known precisely throughoutthe crystal, to it-smaller structures agglomerate to form essentiallywhat resembles a gumball.

Size dimensions of such “gumball-like” structures (describing individualmesoporous carbon-based particles 300A and/or the like) may be about 100nm across (at its widest point). Larger agglomerated particles made upfrom multiple “gumball-like” structures may be an order of magnitudelarger, about 20-30 microns in diameter.

These “gumball-like” structures (individual mesoporous carbon-basedparticles 300A and/or the like) may comprise of multiple FLG structures(electrically conductive interconnected agglomerations of graphenesheets 303B) with Li ions interspersed there-within, at a level of 2-3Li ions in-between each individual graphene layer (made possible by thetuning of the height or gap length between individual graphene layers)tied into a carbon scaffold gradient by joining the larger 3Dgraphene-based particles together to form a thin film.

In contrast, traditional battery electrode production methods typicallyemploy known deposition techniques such as chemical vapor deposition(CVD) or other fabrication techniques, nanotubes, etc., to “grow”structures off a defined fixed substrate or surface. Such known assemblyprocesses and procedures can tend to be very labor intensive, and theymay also permit for the growth of structures of limited thickness,200-300 microns in thickness.

Graphene-on-graphene densification, of multiple FLG, on an originalgumball-based carbon scaffold (individual mesoporous carbon-basedparticles 300A, carbon scaffold 300H, lithiated carbon scaffold 400A,and/or the like) may also result in increased energy density andcapacity. Such densification in target regions of the carbon scaffoldmay also be performed or otherwise accomplished after creation of alarger agglomerated particle comprising multiple mesoporous carbon-basedparticles 300A. Li ions may be plated onto electrode prior to reduction;therefore, Li ion may transition from an ion to a metal state dependenton battery chemistry. Moreover, in an implementation, likeelectroplating, graphene may be grown in a stacked manner on othermaterials, such as plastic, and tuned to obtain a desirable brightand/or smooth finish. Such electroplating processes are reversible andmay include separate but interrelated plating process and a strippingprocess, intended to place the Li ions and/or atoms down (and for thesubsequent removal thereof).

In continual cyclical use of secondary Li ion batteries, involvingmultiple charge-discharge-recharge cycles, surfaces upon whichcarbon-based structures are grown and/or built may eventually roughenedand therefore susceptible to or accommodative of unwanted dendritegrowth. In contrast, techniques employed to produce mesoporouscarbon-based particles 300A and/or the like, as discussed above, preventsuch dendrites from growing, enabled by the usage of Li metalsubstantially free of impurities along with carbon-based graphenestructures to enable high specific capacity values.

Usage of graphene sheets permits for greater exposed surface areaavailable for plating or intercalating operations for the infiltration(referring to non-reactive capillary infusion) of Li ions. Thus, anytendency to go to a certain point anymore is removed; and, fundamentallythe way plating and stripping occurs may be changed (due to the graphenehaving a higher surface-area to volume ratio than other conventionalcarbon-based materials such as graphite). Li ions may be introduced atleast partially relying upon liquid Li; however, given Li'spredisposition for chemical reactivity with surrounding and/or ambientelements, water-based moisture and oxygen must be kept away. Similarly,the introduction of impurities results in deleterious effects.Metal-matrix composites have been studied, in relation to the disclosedcarbon-based structures, regarding usage of Li metallically bonding orotherwise forming a metal-matrix composite with C, therefore offeringadditional options regarding the fine-tunability and management ofreactivity at exposed surfaces.

Li in contact with C may result in circumstances where the free energyof carbide of Li at contact surfaces must be suppressed and/orcontrolled to avoid unwanted reactivity related to spontaneous Liinfiltration in mesoporous carbon-based particle 300A and/or the like.Traditionally, Li, in a liquid phase, typically forms carbonates andother formations due to the chemistry of the electrolyte. However, whatis proposed by the present examples relates to the creation of a stablesolid electrolyte interface (SEI) prior to the introduction of theliquid electrolyte, this is a central concept supportive of thesurprising performance success of the disclosed examples andimplementations.

Moreover, multiple methods and/or processes to affect Li ion interfaceareas may be available. For instance, preparing the surface of liquid Liby alloying with Si and other elements will reduce the reactivity andpromote overall Li ion wetting of larger agglomerated particles, eachcomprising multiple “gumball” structures (mesoporous carbon-basedparticles 300A). In an example, less than 1.5% of Li was observed tohave preferentially moved to exposed surfaces, exposed to theelectrolyte.

FIGS. 5A-5B show various photographs and/or micrographs related ofexample variants of the 3D mesoporous carbon-based particles shown inFIGS. 3A-3J. FIGS. 5A-5B show various photographs and/or micrographsrelated of example variants (variant 500A and variant 500B) of the 3Dmesoporous carbon-based particles shown in FIGS. 3A-3J at variousmagnification levels illustrating internal porosity and microstructure.As can be seen from variant 500A, mesoporous carbon-based particle 300A,300E and/or the like self-assembles upon an initial nucleation, such asin-flight in a microwave plasma-based reactor (as discussed earlier) toform ornate scaffolded agglomerations such as carbon scaffold 300Hsuitable for lithiation to become lithiated carbon scaffold 400A.

FIGS. 5C1-5C3 show examples related to a printed battery featuringpressure-based electrolyte release capabilities. The present batteriesutilize a metal air battery chemistry, illustrated by FIG. 5C1-5C3,which includes an air (cathode) electrode reaction and a metal (anode)electrode reaction. The batteries include a dry carbon electrode withembedded conducting salt (such as ionic liquid), where the carbon isactivated when exposed to moisture in the air. The active metal anodemay be made of, for example, Mg, Zn, Al or other metals, and may or maynot include a carbon-based material. In one implementation, Mg alloy isused for the anode because of its benign biological function and hightheoretical capacity.

In some implementations, biocompatible conductive polymers, such asPolypyrrole (PPy) could be used in combination with carbons and specificoxygen reduction catalysts to create a composite cathode material thatis biocompatible. For the anode, the approach is to usebiocompatible/biodegradable materials such as Mg, Zn, Al, and the likeand as a separator, cellulose and polymer-based materials would be used.Management of toxicity, biocompatibility and biodegradability can becontrolled as independent variables.

The cathode may be made of, for example, graphite, silver chloride,copper chloride, MnO₂, or carbon/MnO₂ in the case of a supercapacitor.In some implementations, the carbon electrode may include anelectrocatalyst to accelerate the reaction. In such implementations, thecarbon electrode surface can be functionalized to absorb CO₂ in the air,to prevent the CO₂ from blocking the electrode reaction. This is becauseCO₂ in the air could undergo a carbonation reaction with theelectrocatalyst (such as alkaline electrolyte), thus changing thereaction environment inside the cell, blocking the gas diffusion layerand limiting access of air by the battery.

In some implementations, the battery includes hydrophobic and/orhydrophilic areas to inhibit and promote wetting and infiltrationspatially across the surface. For example, carbon-based materials can betailored to be hygroscopic (such as hydrophilic) for use within theelectrodes so that when the battery is exposed to air, adsorption ofwater from the air activates the electrode materials. In anotherexample, carbon-based materials can be tailored to be hydrophobic toform a barrier around the battery so that the electrolyte, whenactivated by moisture, will stay within the battery area of thesubstrate. The tailoring of the carbons to be hydrophobic or hydrophiliccan be achieved by, for example, altering the surface energies of thecarbon. In some implementations, this tailoring may be achieved in thereactor when the carbon particles are produced, creating a surface layerthat is stable in air.

In a specific example of electrode materials, shown in FIGS. 1A-1B, theanode is a metal-doped carbon such as metal/graphite. The bulk of theanode, such as a central area, is hydrophilic, such as with aspecifically tailored carbon-based material. When the anode is exposedto air, moisture in the air is adsorbed onto the anode therebyactivating the anode. The cathode can be an air cathode that operatesusing functional carbon, particularly its porous and conductiveproperties. The carbon serves as a gas diffusion layer, controllingdiffusion of water and carbon dioxide across the carbon layer. Thecathode has an embedded electrolyte and a catalyst that are activatedwhen water is introduced. The electrodes are surrounded by a hydrophobicperimeter, which serves as a dam to prevent the activated materials fromspreading to other areas. The perimeter can be made from, for example,carbon that is tailored to be hydrophobic.

In some implementations, the electrolyte may be an ionic conductor andmay be a semi-solid or gel-type compound embedded in a liquid. Theliquid may be, for example, aqueous graphite (with electrochemicalwindow, such as 1.3 V), an organic liquid, or a dry ionic liquid (4-6 Vwindow). The electrolyte may be activated with a hygroscopic additive orwith an ionic liquid bound to a polymer (such as polypyrrole) in thecarbon air cathode.

In some implementations, nanoscopic active materials such as MnO₂ orhydrogen (for the cathode), can be incorporated directly onto or intothe surface of nanostructured carbons. In such a configuration, thenanostructured carbon substrate serves a high-surface-area, 3-D currentcollector for a coating (such as MnO₂) and defines the internal porestructure of the electrode, which facilitates the infiltration and rapidtransport of electrolyte to a nanoscopic MnO₂ phase.

The battery components are fabricated by printing, which may include abinder. Examples of printing materials include chitosan for aqueousliquids (embedded chlorine nitrate is biodegradable) and ionic liquids.Carboxymethyl cellulose (CMC) is an example an organic electrolyte. Anexample of a material for the current collectors is a metal laminatedplastic with a thin graphite layer to reduce contact resistance toelectrode materials.

The printed batteries of the present implementations are compatible withhigh-volume, roll-to-roll manufacturing processes such as gravure andscreen printing. Thus, the present printed batteries may be economicallyproduced.

Applications

The printed batteries can be used, for example, in short-term (dutycycle), single-use events needing a safe, “throw-away” powerrequirement. Example applications include using the printed battery as apower source for smart tags, tracking labels for boxes/packaging (suchas a multi-day international package delivery), electronic accessoriesto be powered for a limited time (such as a display for notebooks), andconsumer products on a retailer's shelf (such as for inventory control).Additional examples include entertainment applications, such as “smart”concert tickets, greeting cards, and toys. In other examples, thebiodegradable (such as biocompatible) nature of the batteries enabletheir use as a power source for medical applications, such as drugdelivery. Applications with larger available footprints will typicallyenable more usable amounts of power to be generated.

Another application of the present printed batteries is that the processof activating battery can also provide an opportunity for analysingcontaminants or hazardous materials that may have been transferred froma user's skin to a sensor connected to the battery.

Yet other myriad applications of the present printed batteries areapparent. For example, the present printed batteries can be used inmedical devices. Moreover, applications of the present printed batteriesarise when used in subcutaneous medical devices, and since medicaldevices are often stored for relatively long periods of time beforebeing used in vivo, there are number advantages of using the two-partaspects of the batteries described herein. As strictly one exampleadvantage, the two-part batteries can be stored for long periods of timebefore being activated (such as when being dispensed to a patient). Thisfeature results in medical devices that have reliably long usability.Strictly as one example, so long as the battery materials do not contactwith moisture or a ‘liquid’ electrolyte (such as so long as theindividual battery components are not activated), the individualseparate components have an expected “shelf life” (such as usable lifein un-activated state) of greater than 5 years.

The biodegradability of a component or combination of components dependson the specific chemistries in use. In some cases, the materials andchemistries are preferentially selected to be biocompatible, independentof biodegradability. The bio-compatibility aspects as well asbiodegradability aspects of a particular battery option can beengineered in accordance with the specific requirements of a specificend-use or specific application.

FIG. 6A-6C shows views of a printed battery that can be activated at apoint-of-use.

FIGS. 7A-8A show self-aligning geometry that self-aligns even inpresence of lateral misregistration.

FIG. 8B shows an example listing of printed battery properties andadvantages.

FIG. 9 illustrates a configuration of an anode and cathodeinterdigitated therewith, both the anode and cathode being disposed on acomponent layer, which is disposed on a substrate layer.

FIG. 10 an exploded view of layers of an example printed battery, suchlayers including elements of a cathode and anode portion, respectively.

FIG. 11 an exploded view of layers of an example printed battery, suchlayers including elements of a cathode and anode portion, respectively.

FIGS. 12A-12B show an example where printed batteries are activated byan external source.

FIGS. 12C-18 show information, targets, properties, and relatedmaterials for printed batteries according to a variety of examples ofthe presently disclosed implementations.

FIGS. 19A and 19B show SEM images, and FIGS. 20A and 20B show TEMimages, of the carbon aggregates of the particulate carbon of thisexample showing graphite and graphene allotropes. The layered grapheneis clearly shown within the distortion (wrinkles) of the carbon. The 3Dstructure of the carbon allotropes is also visible. The carbonallotropes in this example have a 3D structure with a hierarchicalmesoporous, few layer, graphene structure with a specific edge-to-basalplane ratio. In some implementations, the edge-to-basal plane ratio forthe graphene in the present particulate carbon is about 1:10, or about1:100, or from 1:10 to 1:100.

The surface area of the aggregates in this example were measured usingthe nitrogen BET method and the density functional theory (DFT) method.The surface area of the aggregates as determined by the BET method wasapproximately 85.9 m2/g. The surface area of the aggregates asdetermined by the DFT method was approximately 93.5 m2/g.

In contrast to conventionally produced carbon materials, the microwaveplasma reactor produced carbon particles and aggregates in this examplecontained graphite and graphene had high purity, high electricalconductivities, and large surface areas. Additionally, these particleshad Raman signatures indicating a high degree of order and contained noseed particles.

In some implementations, the particulate carbon in the present gassensors contains doped carbon materials (such as carbon doped with H, O,N, S, Li, Cl, F, Si, Se, Sb, Sn, Ga, As, and/or other metals), undopedcarbon materials, or combinations thereof. Doped carbon can also includecarbon with a matrix allotrope doped with carbon atoms (not in thematrix structure) and/or doped with other types of carbon allotropes.Doped carbon materials can also be doped with functional groups, such asamine (NH3) groups. In some implementations, doped carbon materials areformed using a dopant material, where the dopant material is introducedwithin a gas, liquid, or colloidal dispersion and fed into a reactorthat is used to produce the doped particulate carbon. For example,dopant materials can be combined with a hydrocarbon precursor materialand cracked in a reactor (such as a microwave plasma reactor or athermal reactor) to produce a doped particulate carbon.

In some implementations, the particulate carbon in the present gassensors contains nano-mixed particulate carbon. In some implementations,the surface area, structure, and/or surface activity of the presentparticulate carbon materials are tuned by nano-mixing the carbonparticles within the carbon materials with particles of other materials.In some implementations, particles of nano-mix additive materials can bebeneficially integrated with particles of the graphene-based carbon on aparticle level, which shall be referred to as nano-mixing in thisdisclosure. The average diameter of the particles of the nano-mixadditive material and the graphene-based carbon materials in thenano-mixed particulate carbon can be from 1 nm to 1 micron, or from 1 nmto 500 nm, or from 1 nm to 100 nm, or can be as small as 0.1 nm. In someimplementations, the nano-mix additive material and the graphene-basedcarbon material are chemically bound, or are physically bound, togetherin the nano-mixed particulate carbon. In some implementations, thenano-mixing involves introducing nano-mix additives during particulateformation (such as during a hydrocarbon cracking process in a microwaveplasma reactor or in a thermal reactor) such that the nano-mix additivematerial is integrated into the graphene-based carbon material as thecarbon material is produced, rather than combining a carbon raw materialwith an additive in a later process as in certain conventional methods.In some implementations, the nano-mix additive material can beintroduced as a gas, liquid, or colloidal dispersion into a reactor thatis used to produce the nano-mixed particulate carbon. As an example,silicon can be input into a reactor along with a hydrocarbon process gas(or other carbon-containing process material such as a liquid alcohol)to produce silicon nano-mixed with graphene, graphene-based carbonmaterials, and/or other carbon allotropes. In other examples, theresulting nano-mixed particulate carbon of the present implementationscan contain particles of O, S, LixSy (where x=0-2 and y=1-8), Si,Li22Si5, Li22-xSi5-y (where x=0-21.9, and y=1-4.9), and Li22-xSi5-y-zMz(where x=0-21.9, y=1-4.9, z=1-4.9, and M is S, Se, Sb, Sn, Ga, or As),and/or other metals.

In some implementations, the particulate carbon to be used in thepresent gas sensors are produced and collected, and no post-processingis done. In other implementations, the particulate carbon is producedand collected, and some post-processing is done. Some examples ofpost-processing include mechanical processing, such as ball milling,grinding, attrition milling, micro-fluidizing, jet milling, and othertechniques to reduce the particle size without damaging the carbonallotropes contained within. Some examples of post-processing includeexfoliation processes such as shear mixing, chemical etching, oxidizing(such as Hummer method), thermal annealing, doping by adding elementsduring annealing (such as O, S, Li, Si, Se, Sb, Sn, Ga, As, and/or othermetals), steaming, filtering, and lypolizing, among others. Someexamples of post-processing include sintering processes such as SPS(Spark Plasma Sintering, such as Direct Current Sintering), Microwave,and UV (Ultra-Violet), which can be conducted at high pressure andtemperature in an inert gas. In some implementations, multiplepost-processing methods can be used together or in series. In someimplementations, the post-processing can produce the functionalizedcarbon nanoparticles or aggregates described herein.

The particulate carbon described herein can be combined with a secondphase of material to create composite films. These composite films canbe fabricated utilizing different methods to create specific detectorresponses.

In an example, solid carbon particles (such as particle size from 0.3microns to 40 microns) and polymer beads (such as ball mixed for sizereduction and improved aggregation) can be mixed in a ratio of 90:10respectively (or in ratios from 95:10 to 5:95). This mixture can then becast onto a substrate (such as one containing prefabricated electrodes,or an antenna platform), and then treated (such as using a lowtemperature, post treatment in an inert gas oven, a reactive gas oven,or a vacuum oven).

In another example, the mixing of the solid carbon particles and polymerbeads described in the example above can be further combined with asolvent to form an ink, which can then be deposited onto a substrate(such as cast using doctor blade or printed). After deposition, the filmcan then be treated at a low temperature to remove the solvent andconsolidate the film.

In another example, particulate carbon can be encapsulated with apolymer to form colloidal core-shell structures that can be printed ontoantenna platform using various techniques including inkjet printing,aerosol spray coating, spin coating and roll coating.

In another example, the particulate carbon can be combined with asoluble polymer to form jettable inks for printing. In suchapplications, conductive binders, such as silver flakes/particles, canalso be added to tune the dielectric properties (such as atparticle-particle contact points).

Electrochemical Sensors

FIG. 21 is a plan view schematic of an electrochemical gas sensor 2100,in accordance with some implementations. The gas sensor 2100 has acircuit containing a first electrode 2110 printed from a conductive ink,a second electrode 2111 printed from a conductive ink, a non-volatileelectrolyte 2120 that electrically couples the first electrode 2110 tothe second electrode 2111, a signal generator 2160 (shown as a voltagesource), and a measurement (or detection) circuit element 2170 (shown asa mega-Ohm resistance measurement in the figure, but could also be acapacitance, impedance or other electrical measurement in otherimplementations). The presence of a target chemical produces adetectable signal between the two electrodes 2110 and 2111. For example,the change in the resistance of the circuit, the capacitance of thecircuit, and/or the impedance of the circuit can be used as a detectionsignal. One of the electrodes 2110 or 2111 serves as the sensingelectrode, and the other is the counter electrode. In someimplementations, one or both of the electrodes 2110 and 2111 containparticulate carbon (such as the particulate carbon described herein),silver particles, metal particles, conductive oxide particles (such asindium tin oxide and/or fluorine-doped tin oxide particles), or otherconductive particulate materials (including any aspect ratioparticulates, such as those shaped as spheroids, rods, and wires). Inother implementations, one or both of the electrodes 2110 and 2111contain carbon allotropes such as, but not limited to, graphene,graphenes (graphene-based materials), graphene oxide, reduced grapheneoxide, graphite oxide, graphite intercalation compounds, graphite,graphene, carbon nano-onions, diamond, p-type diamond, n-type diamond,glassy carbon, amorphous carbon, activated carbon, carbon black and/orcarbon nano-tubes. The carbon materials in the first electrode 2110 maybe the same as or different from the carbon materials in the secondelectrode 2111. In one implementation, the first electrode 2110 includesa high surface area, highly conductive carbon allotrope combined with aredox mediator such as from the class of metallocenes (such asferrocene), while the second electrode 2111 includes a conductive inkwith a low surface area carbon allotrope with no redox mediator. Invarious implementations, the first electrode 2110, second electrode2111, and electrolyte 2120 are all printed on a substrate 2150, such asby ink-jet printing. In some implementations, the substrate 2150 is arigid or flexible material, such as paper, such as paper used in a labelmaterial. Some other non-limiting examples of substrate materials arepolymers (such as polyethylene terephthalate, or polypropylene), andcardboard. One benefit of the present gas sensors is that they can beprinted on many different substrates, in accordance with someimplementations.

In some implementations, the electrolyte 2120 can be inkjet printed andcontain materials such as polymer electrolytes, ceramics, or monomersthat solidify into a suitable solid electrolyte. Examples of liquidelectrolyte materials include ionic liquids, such as1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide,1-butyl-3-methylimidazolium hexafluorophosphate,1-butyl-3-methylimidazolium tetrafluoroborate,1-hexyl-3-methylimidazolium tris(pentafluoroethyl)trifluorophosphate,1-butyl-1-methylpyrrolidinium bis(trifluoromethylsulfonyl)imide,ethylammonium nitrate, and tetrabutylmethylammoniumbis(trifluoromethylsulfonyl)imide. Ionic liquid monomers with acrylatefunctional groups can be in-situ polymerized to make polymer ionicliquids, such as poly(tetrabutylphosphonium3-sulfopropylacrylate) orpoly(tributylhexylphosphonium 3-sulfopropylacrylate). Alternatively,solid polymer electrolytes could be used, which include a copolymer ofpoly(tetrafluoroethylene) with poly(sulphonylfluoride vinyl ether)(commercial example includes Nafion 117 from DuPont),poly(dimethyldiallyammoniuim chloride), plasticized poly(vinylchloride)containing tetrabuylammonium hexafluorophosphate, and poly(ethyleneoxide) complex with silver trifluoromethane sulfonate. In someimplementations, the electrolyte 2120 contains a reactive chemistryadditive and serves as a sensing material (such as and neither of theelectrodes contains a reactive chemistry additive). In such cases, thepresence of the target chemical is detected by measuring a change in asignal (such as the capacitance of the circuit) in the sensor 2100 dueto the change in the electrical properties of the electrolyte. Not to belimited by theory, in some cases, charge arising from electron transferfrom a reactive chemistry additive (such as a redox mediator material)compound to a target molecule (such as the compound of interest (such asanalyte or target chemical), or products arising from the compound ofinterest) affects the electrical properties of the electrolyte, therebyaffecting the signal in the gas sensor 2100. The electrolyte 2120 canhave as a solvent: water, polar organic solvents, ionic liquids, orpolymer electrolytes, for instance. In some implementations, theelectrolyte can be printed from a class of polymer electrolytes or ionicliquids. In some cases, the sensing reactions (such as the interactionof the sensing material with the analyte) in any of the gas sensorsdescribed herein occur at room temperature and ambient pressure, or atelevated temperatures (such as from 30° C. to 80° C.). In some cases,photons (such as visible light, or UV light) are introduced to thesensing material of any of the gas sensors described herein to increasethe rate of the sensing reactions.

In other implementations, one or both of the first and second electrodes2110 and 2111 serves as a sensing material, and includes a redoxmediator, where the redox mediator may be in the form of a polymer or asolution. That is, in some implementations, at least one of the firstelectrode, the second electrode, or the electrolyte material contains aredox mediator.

The one or both of the first and second electrodes 2110 and 2111, or theelectrolyte 2120 can include a redox mediator, which is a compound thatdonates or receives a proton or an electron from an electrode andperforms reduction or oxidation of a substance in bulk solution awayfrom the electrode by transferring this electron or proton to/away fromthe substance. FIG. 22 is a table that lists non-limiting examples ofpossible redox mediators that may be used in the presentimplementations. In some implementations, the redox mediator is anorganometallic material, such as a metallocene (such as ferrocene). Invarious implementations, the redox mediator is a polymer or a solutionin which there is non-covalent tethering of the redox mediator to thecarbon one or more of the gas sensor components (such as the first orsecond electrodes 2110 and 2111, and/or the electrolyte 2120), covalenttethering, or the redox mediator is untethered to the carbon.Tethering-whether covalent or non-covalent-causes the redox mediator tobe immobilized by binding it to a component of the sensor (such as thepositive electrode). Covalent tethering of the mediator refers tochemically bonding a material that has redox activity to a carbon (suchas using organic chains comprised of, for instance, combinations ofcarbon, oxygen, nitrogen, silicon, sulfur, and/or hydrogen).

FIG. 23 shows an example of an electrochemical gas sensor 2300 inanother implementation of an electrochemical sensor, where a firstelectrode 2310 and a second electrode 2311 are configured asinterdigitated fingers to increase the area for electrical interactionbetween the electrodes, which can be beneficial for example in caseswhere the electrolyte contains the sensing material (such as reactivechemistry additives). Additionally, such an interdigitated electrodegeometry can be used to tune the capacitance of the sensor element toallow it to be integrated with other circuit elements moreadvantageously. In some implementations, the first and second electrodes2310 and 2311 are printed using carbon-based conductive inks (optionallycontaining one or more redox mediators), as described in relation to thesensor 2100 of FIG. 21 . An electrolyte 2320, which can include a redoxmediator (as described in relation to FIGS. 21 and 22 ), can be printedas a layer over the electrodes 2310 and 2311. In the illustratedimplementation, the electrolyte 2320 is configured as a circular layer(such as by applying a droplet of the electrolyte during fabrication ofthe sensor). However, in other implementations the electrolyte 2320 canbe formed (such as inkjet printed or cast) in other geometries, such asa rectangular layer, or other patterned shape to impact the electricalproperties of the sensor circuit. Some non-limiting examples ofmaterials for the electrolyte are polymers (such as poly (etherurethane) (PEUT), polyepichlorohydrin (PECH), polyisobutylene (PIB), andalkyl cellulose), ceramics, or monomers that solidify into a suitablesolid electrolyte. The first electrode 2310, second electrode 2311, andelectrolyte 2320 can all be printed on a flexible or rigid substrate2350, where the substrate 2350 may be, for example, an SiO₂-coated paperor polymeric material.

In some implementations, the electrodes and electrolytes of the presentimplementations contain the particulate carbon described herein and aretuned to sense the target chemical. In some implementations, tuning theparticulate carbon materials includes functionalizing the particulatecarbon to be sensitive to certain materials. For example, theparticulate carbon can contain one or more reactive chemistry additiveswhich react with a target chemical to be detected. Some non-limitingexamples of target chemicals moieties that can be detected by thesensors of the present disclosure include, but are not limited to,acetone, ammonia, carbon monoxide, ethanol, hydrogen peroxide (H₂O₂),nitro (NO₂) groups, oxygen, and water (such as to detect humiditylevels). Characteristic interactions between these chemicals andreactive chemistry additives of one or more of the gas sensor componentsare used to detect the presence of these chemicals. For example, NO₂groups withdraw electrons, NH₃ gas is an electron donor, CO₂ gas is anelectron donor, acetone is a neutral molecule, H₂O₂ is an oxidizer, andethanol is an electron donor. When a gas species interacts with areactive chemistry additive in the sensing material, these types ofinteractions change the electrical properties (such as the conductivity,or the complex impedance) of the sensing material, which causes a changein the measured response from the gas sensor indicating the presence ofthe species.

In an example, a sensing material in a gas sensor contains particulatecarbon containing p-type doped graphene semiconductors, which have aresponse towards NO₂, CO₂, or NH₃ gases. NO₂ gas or NO₂ containingmolecules adsorb/desorb on a graphene surface via three adsorptionconfigurations: nitro, nitrite, and cycloadditions. During theseconfigurations, there is a charge transfer between NO₂ molecules and thep-type graphene molecules. The electron withdrawing effect of NO₂increases the hole-density which leads to a decrease in resistance (or achange in the complex impedance spectrum). CO₂ and NH₃ are donors, sothe resistance of the p-type doped graphene semiconductors increases (orthe complex impedance spectrum changes) due to a depletion in holedensity.

In another example, a sensing material in a gas sensor containsparticulate carbon containing n-type graphene composites, which can beused for acetone sensing. In graphene-zinc-ferrite composites, surfaceoxygen sp hybrid orbitals interact with acetone to form CO₂ and H₂O andrelease free electrons which decreases the resistance (or change thecomplex impedance) of the sensing material. In a further example, agraphene composite with iron (II) reacts with H₂O₂ to produce O₂ and Fe(III). Either O₂ can be detected, or UV can be used to check thewavelength of the Fe (III) complex.

In some implementations, the carbon allotropes within the particulatecarbon in the present sensors can be tuned to detect the desiredchemical by utilizing a certain microstructure, such as the porosity orcurvature (such as curved graphene) of the carbon. The carbons cancontain sp₃, sp₂ and/or sp hybrid orbitals, or a combination of these.In other implementations, tuning can be achieved by adding reactivechemistry additives in the form of functional groups to the carbon, suchas oxygen, ketones, or carboxyl. The tuning in the variousimplementations may be achieved during initial production of the carbon,and/or by post-processing after the carbon has been made. Thepost-processing, as described herein, can include steps such as changingthe surface area of the carbon material (such as by ball milling),changing the conductivity, adding functional groups, or a combination ofthese.

In an experimental run, a sensor similar to that of FIG. 23 was used todetect the presence of hydrogen peroxide. The interdigitated fingers inthis example contained the particulate carbon described herein. Theredox mediator solution was 10 μL of 5 mMbis(pentamethylcyclopentadienyl) iron (II), 100 mM tetraethylammoniumtetrafluoroborate, and 25 mM KOH in butylmethylimidazoliumtetrafluoroborate. The sensor was activated by applying a voltage of 1.0V in the absence of peroxide and then allowed to equilibrate for 5minutes to establish a baseline current. The sensor was then put into anatmosphere containing peroxide (single digit parts per million to partsper billion) for 1.0 hr, after which a voltage of 1V was applied and thecurrent was measured. The results are shown in Table 1 below.

TABLE 1 Sample experimental results for electrochemical sensor Testcycle 1 Test cycle 2 Current 2.63 μA 19.7 μA 20.5 μA Energy 311 nWh 1912nWh 1973 nWh

As can be seen from Table 1, the baseline currents increasedapproximately 650%—from 2.63 μA to 19.7 μA—and remained constant (20.5μA) for the second hold/test cycle. Thus, the electrochemical sensordemonstrated the ability to detect peroxide with high sensitivity usinglow amounts of electrical power.

High Frequency Sensors

Some electrochemical sensors utilize direct current (DC) electricalsignals to detect changes to a sensing material (such as changes incharge carrier concentration causing a change in resistance to indicatechemistry, and/or changes in molecular structure causing a change incapacitance to indicate chemistry). While such DC gas sensors arecapable of sensing low levels of chemistry, the detection range withoutcostly equipment (such as utilizing high power energy sources) to drivechemical reactions makes widespread adoption impractical for mostapplications. In the present implementations, alternating current (AC)signals are used to detect characteristic, reversible impedanceresponses of a sensing material. In some such gas sensors, amulti-frequency AC signal (such as RF current with a range offrequencies) is applied to a sensing material within a sensing circuitand the complex impedance of the circuit is detected. The frequencies ofthe AC signals used in such “high frequency” gas sensors are typicallygreater than 1 kHz, or are from 1 kHz to 20 GHz, or are from 100 kHz to20 GHz.

High frequency gas sensors contain AC circuits with a sensing materialincorporated. The geometries and materials in the AC circuits can betuned to be sensitive to certain frequency ranges, and the compleximpedance of the AC circuit changes upon interaction with an analytethat changes the complex impedance of the sensing material. In general,the complex impedance of a material within the AC circuit will affectthe signals detected from the circuit and can be tuned to tune theresponse of the circuit. For example, the sensing material can contain acarbon material, the properties of the carbon material can affect thecomplex impedance, and therefore the complex impedance of a carbonsensing material and a sensing circuit containing that material can becontrolled by specifically tuning the properties of the carbon materials(such as the structure of the carbon materials, the types of allotropespresent, and the concentration of defects in any ordered carbonallotropes present).

In some implementations, high frequency gas sensors contain a structuredmaterial within the sensing material. The complex impedance of astructured material is a result of the inherent materials propertiesforming the structure as well as the geometry of the structure, such asthe pore size, the pore spacing and the macroscopic shape of thematerial. In the case of composite structured materials, thedistribution of the materials with different properties also affects thecomplex impedance of the material. For example, electrically conductivematerials (such as the particulate carbons described herein) can bestructured into a mesoporous structure and be decorated with othermaterials such as dielectrics or permeable materials. In someimplementations, the structure, composition, distribution of materials,and/or the concentration of impurities and/or defects are changed totune the complex impedance of a structured sensing material within ahigh frequency gas sensor. Such a structured sensing material isbeneficial in high frequency resonant gas sensors because they contain avariety of random paths and path lengths available for conduction atmany frequencies, which can provide a sensor with a wide bandwidth offrequencies with which to detect a target analyte. In someimplementations, the structured materials (such as with the particulatecarbon described herein) are frequency selective materials, which areused in high frequency circuits within the present gas sensors.

In some implementations, dielectric polarization modification impedancespectroscopy is utilized, which is a low-cost method for detecting lowconcentrations of analytes (such as volatile gases or vapors) in a gassensor. In some implementations, an impedance spectroscopy measurementcan be used to detect the modulation of properties of a sensing materialcontaining reactive chemistry additives (such as a structured sensingmaterial containing particulate carbon and a redox mediator in thepresence or absence of an analyte). For example, selective frequencyinterrogations of S21 (such as the transmission of a high frequencysignal through an AC circuit or system) and S11 (such as the reflectanceof a high frequency signal from an AC circuit or system) can be used todetect a change in the complex impedance of the sensing material and/orcircuit (or system) as a whole. The operation of the gas sensor relieson a change in the measured S21 or S11 value upon exposure to ananalyte.

The combination of such high frequency gas sensors (such as utilizingimpedance spectroscopy) and the unique properties of the particulatecarbon described herein (such as structure, surface area, andconductivity) enables gas sensors that are able to generate the sameresults as the more costly counterparts (such as detecting an analytewith concentrations in the parts per million (ppm) or parts per billion(ppb) ranges) at a greatly reduced price, and an improved ease ofadoption and portability. The low power requirement of the presentimplementations allows for the system to be powered by battery systemsand in some cases using energy harvester systems. Additionally, theimaginary part of the complex impedance of the sensing materialsdescribed herein have spectral signatures (such as peaks in the spectra)that can discriminate one molecular arrangement from others, enablingthe detection of several molecules with one sensor.

FIG. 24 shows an example implementation of a chemical sensor 2400 inwhich high frequency (such as impedance) spectroscopy is used as thedetection method. Sensor 2400 includes a first electrode 2410, a secondelectrode 2411, and a dielectric 2420 sandwiched between the electrodes2410 and 2411, all of which are arranged on substrate 2450. In someimplementations, the electrodes 2410 and 2411 and/or the dielectric 2420are printed from inks on the substrate 2450. Substrate 2450 may be rigidor flexible, for example, a label. In some cases, a device may be formedon both sides of a substrate. In some implementations, the electrodes2410 and 2411 contain the particulate carbon described herein), silverparticles, metal particles, conductive oxide particles (such as indiumtin oxide and/or fluorine-doped tin oxide particles), or otherconductive particulate materials (including any aspect ratioparticulates, such as those shaped as spheroids, rods, and wires). Inother implementations, one or both of the electrodes 2410 and 2411contain a carbon allotrope such as, but not limited to, graphene,graphene oxide, carbon nano-onions, and/or carbon nanotubes. In someimplementations, one electrode includes a metal while the otherelectrode does not. One or both electrodes 2410 and 2411 and/ordielectric 2420 can include a reactive chemistry additive (such as aredox mediator), as described in reference to the electrochemicalsensors above, which is tuned to one or more target analyte (such asvolatile gas or vapor) species.

In operation, an AC source 2430 applies AC signals having a range offrequencies (such as greater than 1 kHz, or from 10 kHz to 20 GHz, orfrom 10 kHz to 1 GHz, or from 500 kHz to 20 GHz, or from 500 MHz to 20GHz) to the sensor 2400, and a detection circuit 2460 detects a changein impedance at specified frequencies when the target substanceinteracts with (such as is absorbed into, or adsorbed onto) the sensingmaterial. In some implementations, the sensor 2400 uses an impedancespectroscopy technique, in which specific target analyte chemicalsinteract with the sensing material (such as containing the particulatecarbon described herein) causing a change in the complex impedance ofthe sensing material. The change in the complex impedance can then bemeasured by the circuitry 2460, and the measured change used fordetecting the target substance. In some implementations, the sensingmaterial contains tailored carbon and a reactive chemistry additive withelectrons that interact with the target compound and change theresonance frequency.

High Frequency Resonant Sensors

One type of a high frequency gas sensor is a resonant gas sensor. Insome implementations, a resonant gas sensor contains one or more sensingmaterials, and changes to the resistivity and permittivity of thesensing materials result in changes to the resonant behaviour of thesensor. In some implementations, such a resonant gas sensor can beprinted and utilize small electronics (such as a small IC chip), suchthat it can be miniaturized and produced at low cost. Such low-costminiature resonant gas sensors have a myriad of applications includingproduct labels on food packaging, shipping labels on packages, andportable hazardous/toxic gas sensors. In some implementations, low-costresonant gas sensors are enabled by the particulate carbon materialsdescribed herein, which improve the resonant gas sensor sensitivityallowing for low power signals to produce adequate responses. Forexample, the high the surface area and mesoporous structure of theparticulate carbon allows more analyte vapors to enter into thestructure and increases the changes in the sensing material resistivityand permittivity for a given analyte concentration. In someimplementations, the sensing materials or materials making up the otherelements (such as with the particulate carbon described herein) containfrequency selective materials, which are used to tune the resonantfrequencies of the resonant circuits within the present gas sensors.

In some implementations, the resonant gas sensors contain pickupelectrodes to provide AC signal power input to the sensing materials anddetect an output from the sensing materials. The geometries of theconstituent elements can be tuned in order to produce a resonantstructure with certain frequency response in the sensor. In addition,the materials properties (such as resistivity and/or complexpermittivity) of the sensing material can also be tuned to form aresonator structure or composite with a certain spectral frequencyresponse. Tuning the materials properties and resonant structuregeometries can be advantageous to enhance the performance of the gassensor to be more sensitive in certain frequency ranges.

In some implementations, a resonant gas sensor system includes amicroprocessor, which provides a signal to a transducer (such as anantenna) that drives a sensing material in the resonant gas sensor overa specific frequency range. The microprocessor can also detect theresponse (such as the complex impedance spectrum of the sensor). Indifferent cases, the response can be a reflected AC signal (such as S11)or a transmitted AC signal (such as S21). The sensing material can beintegrated into the transducer or be a separate element. Differentresonant gas sensor architectures are described below. In some cases,the response is compared to a database (such as a library) of resonancespectra for a variety of molecular chemistries related to certainmolecules of interest (such as those in explosives or rotting foods). Insome implementations, the functionality of the detector and transducerare integrated into a single, monolithic, patterned film structure,optionally integrated with other electronics such as an integratedmicroprocessor and/or communication chip (such as to communicate adetection event to another device). The microprocessor (and otheroptional integrated electronics) can be powered using an integratedbattery or using energy harvesting structures (such as using an antennathat absorbs RF energy or a photocell that absorbs light, coupled to anintegrated capacitor to store the harvested energy). In some cases, suchan integrated sensor can contain a resonant structure with engineeredproperties (such as conductivity, and geometry) to minimize the antennaabsorption loss at high frequency.

In some implementations, a resonant gas sensor contains a set ofelectrically conductive elements that form a resonant structure. Theresonant structure itself exhibits resonance or resonant behaviour, thatis, it naturally oscillates at some frequencies, called its resonantfrequencies, with greater amplitude than at others. These resonantstructures within the sensors are used to select specific frequenciesfrom a signal (such as the signal provided by the microprocessor in theresonant gas sensor systems described herein). For example, a resonantgas sensor can contain two conductive electrodes surrounding and/orelectrically coupled to a dielectric or an electrically conductive gassensing material, all of which form a single resonant structure (alongwith other components of the system, in some cases). In another example,a transducer (such as an antenna) can be excited with a signal, and thesensing material can be arranged adjacent to the transducer such thatthe complex impedance of the sensing material impacts a detectedresponse. In some cases, the electrode(s) and/or the gas sensingmaterial can contain the particulate carbon described herein. In somecases, the electrode(s) and/or the gas sensing material can be printedand/or be deposited from a liquid, gas or ink dispersion.

In some cases, the resonant structures described above can beincorporated into the resonant gas sensor circuit to form an LC tankcircuit. For example, a coiled antenna can be used as an inductiveelement, and a sensing material between two electrodes can be used as acapacitive element, and the inductive and capacitive elements can beconnected in parallel or in series to form a tank circuit in a resonantgas sensor. In some implementations, a single transducer structure (suchas a coiled antenna) can contain (or be formed from) the sensingmaterial, and also provide the inductive and capacitive elements of thetank circuit. Such multi-functional transducers can be driven by amicroprocessor, and upon interaction with an analyte the transducermaterial properties change, which change the characteristic response ofthe gas sensor circuit, which in turn can be measured by detectioncircuitry to detect the presence of an analyte. In other cases, thetransducer does not contain sensing materials, and the sensing materialschange the properties of one or more elements within the tank circuit(such as the capacitance of a capacitive element), which change thecharacteristic response of the circuit, which in turn can be measured bydetection circuitry to detect the presence of an analyte.

When a gas sensitive material interacts with an analyte, the complexelectrical materials properties of the permittivity ε=ε′−jε″ (where j isthe imaginary unit) and permeability μ=μ′−jμ″ change. In a resonant gassensor, the varying material properties can lead to a change in the wavepropagation of a signal (such as a multi-frequency signal provided by amicroprocessor) through a resonant structure (such as an LC tankcircuit, an antenna, or a microstrip line). In addition to the materialsproperties, the wave propagation of a signal in a resonant gas sensoralso depends on the geometry of the structures formed by the elements ofthe sensor. In some cases, the resonant structures in the resonant gassensor contain one or more waveguides, and the wave propagation of asignal also depends on the design of the waveguide(s). Generally,electromagnetic waves are guided to a desired transmission mode byrestricting their expansion in one or two dimensions. One transmissionstructure for waves with a transversal electromagnetic mode (TEM) is theplanar microstrip line, consisting of a strip conductor and a groundplane either separated by a dielectric substrate or separated by adielectric material on a single side of a substrate. The two-dimensionalstructure of microstrips make them well suited for miniaturization andintegration with other components and, because of the planar structure,they can be fabricated conventionally by thick or thin film technology.In some cases, the circuit elements (such as resonant structures) areformed (such as by printing) on one side of a substrate to create aresonator (such as a microstrip line with co-planar electrodes separatedby a dielectric gap), while in other implementations, the elements areformed (such as by printing) on both sides of a substrate to create aresonator (such as a patch antenna separated from a ground planeelectrode by a dielectric substrate containing a sensing material). Thesubstrate can be many different materials including rigid or flexiblematerials, those with suitable dielectric properties, a polymer sheet,or paper. In some cases, a base layer can be pre-deposited on thesubstrate to act as an anchoring layer to absorb part of the deposited(such as printed) material and or to create a barrier to preventabsorption of the deposited material into the substrate (such as paper).

FIG. 25A shows a non-limiting example of a resonant gas sensor 2500Ainside view and plan view, including a substrate 2510A, a transducer2520A, a microprocessor 2530A, and a ground electrode 2540A, inaccordance with some implementations. A first terminal of themicroprocessor 2530A is electrically coupled to a first terminal of thetransducer 2520A, and the ground electrode 2540A completes the circuitfrom a second terminal of the transducer to a second terminal of themicroprocessor 2530A. In this example, the ground electrode is connectedto the second terminal of the transducer 2520A and to the secondterminal of the microprocessor 2530A through vias in the substrate (notshown). The transducer 2520A in this example is a spiral with successiveloops with different dimensions. The microprocessor 2530A provides ACsignals at different frequencies to the first terminal of the transducer2520A and measures the response (either reflected from the transducer2520A or transmitted through the transducer 2520A, in differentimplementations). In this example, the transducer 2520A contains asensing material (such as a redox mediator), which is sensitive to ananalyte, such that when the resonant gas sensor 2500A is exposed to theanalyte, the complex impedance of the transducer 2520A changes, and theresponse detected at the microprocessor 2530A changes indicating thedetection of the analyte. In other words, the complex permittivityand/or permeability of the sensing material changes upon exposure to ananalyte, which changes the resonant frequency of the sensor circuitindicating the detection of the analyte.

FIG. 25B shows an example of a response from a resonant gas sensor (suchas 2500A in FIG. 25A) in the presence of an analyte of interest. Thex-axis in the plot in FIG. 25B is frequency (from 1 MHz to 5000 MHz),and the y-axis is the reflected signal from the transducer (such aselement 2520A in FIG. 25A) (such as S11, which is the signal reflectedback from the first terminal of the transducer) in dB. The troughs inthe plot in FIG. 25B indicate the resonant frequencies of the circuit,where the AC signals are not reflected (such as dissipated) in theresonant circuit. These troughs can change depending on the type andconcentration of an analyte present, and in some cases can be comparedto a library to determine the identity of a detected analyte species.Since the location of the troughs depends on the resonant frequencies ofthe entire gas sensor circuit, in some implementations, a library ofanalyte species and concentrations is created for a specific resonantgas sensor design and materials set.

FIG. 25C shows a non-limiting example of a resonant gas sensor 2502Cinside view and plan view, including a substrate 2510C, a transducer2520C, a microprocessor 2530C, a ground electrode 2540C, and a sensingmaterial 2550C, in accordance with some implementations. The resonantgas sensor 2502C is similar to the resonant gas sensor 2500C, andfurther includes a separate sensing material 2550C disposed above and inbetween successive loops of the spiral transducer 2520C. In thisexample, the sensing material is sensitive to an analyte, such that whenthe resonant gas sensor 2502C is exposed to the analyte, the frequencyresponse of the resonant circuit formed by the transducer 2520C andsensing material 2550C changes, and the response detected at themicroprocessor 2530C changes indicating the detection of the analyte.The change in frequency response in this example can be caused by achange in the inductance of the transducer 2520C and/or a change in thecapacitance between successive loops of the transducer 2520C, whichchange the resonant frequencies of a tank circuit formed by thetransducer 2520C and sensing material 2550C. In other words, the complexpermittivity and/or permeability of the sensing material changes uponexposure to an analyte, which changes the resonant frequency of thesensor tank circuit indicating the detection of the analyte.

FIG. 25D shows a non-limiting example of a resonant gas sensor 2504D inside and plan views. The resonant gas sensor 2504D includes a substrate2510D, a transducer 2520D, a microprocessor 2530D, a ground electrode2540D, a second electrical connection 2542D, a sensing material 2550D,and a capacitive element 2560D, in accordance with some implementations.The resonant gas sensor 2504D is similar to the resonant gas sensor2500D, and further includes a capacitive element 2560D. The capacitiveelement 2560D in this example is formed from interdigitated electrodes2562D and 2564D. In this example, the capacitive element 2560D has thesensing material 2550D disposed on and between the interdigitatedfingers 2562D and 2564D. In this example, the capacitive element 2560Dis wired in parallel with the transducer 2520D; the ground electricalconnection 2540D is electrically coupled to electrode 2562D of thecapacitive element 2560D, and the second electrical connection 2542Dcouples the electrode 2564D of the capacitive element 2560D to the firstterminal of the transducer 2520D (as described in resonant gas sensor2500A in FIG. 25A). Therefore, an LC tank circuit (with the inductiveelement and capacitive element in parallel) is formed from thetransducer 2520D and the capacitive element 2560D in this example. Inthis example, the sensing material 2550D (such as a redox mediator) issensitive to an analyte, such that when the resonant gas sensor 2504D isexposed to the analyte, the capacitance of the capacitive element 2560Dchanges, and the response detected at the microprocessor 2530D changesindicating the detection of the analyte. In other words, the complexpermittivity and/or permeability of the sensing material changes uponexposure to an analyte, which changes capacitance of the capacitiveelement 2560D and the resonant frequency of the sensor tank circuitindicating the detection of the analyte. One advantage of separateinductive and capacitive elements (such as shown in resonant gas sensor2504D) is that the resonant frequency of the tank circuit can be tuned.One example of this is lowering the resonant frequency to a lowerfrequency range (such as from about 20 GHz to about 1 GHz) to reduce thecost of the electronics required to drive the sensor circuit.

FIG. 25E shows a non-limiting example of a resonant gas sensorcontaining a substrate 2510E, a transducer antenna 2520E, and acomposite detecting film 2550E for sorption of an analyte (such asvolatile organic solvent vapors), in accordance with someimplementations. The composite detecting film 2550E contains astructured particulate conducting phase encapsulated with a polymericbinder. Insets 2570E and 2580E show schematics of the particulateconducting phase 2572E encapsulated by the polymer binder 2574E. Inset2580E shows a volatile gas (or more generally, an analyte) adsorbed bythe polymer binder and/or the interior surfaces of the particulatecarbon. In some implementations, the polymer binder contains one or morereactive chemistry additives, which interact with an analyte and causethe electrical properties of the sensing material 2550E to change. Inother implementations, a reactive chemistry additive (such as adissolved salt) can be deposited on and within the pores of theparticulate carbon. In some cases, the reactive chemistry additives canbe incorporated into the particulate carbon and the polymer binder tofurther improve the sensitivity of the sensing material. In some cases,the reactive chemistry additive can be added to the particulate carbonand the sensing material can contain the particulate carbon and nopolymer binder. Inset 2590E shows schematics of graphene sheets 2592Eand the porous 3-dimensional structure 2594E of the particulate carbonin the composite detecting film 2550E. Some non-limiting examples of thestructured particulate conducting phase can contain 3-dimensionallystructured microporous or mesoporous graphene-containing particles, orthe particulate carbon described herein. Some non-limiting examples ofpolymeric binder include PEUT, PECH, PIB, and alkyl cellulose. Suchstructures are beneficial to detect analyte species and concentration inresonant gas sensors because they produce characteristic, reversibleimpedance responses that can be measured (or transduced) with a highfrequency (resonant) antenna element.

FIG. 25F shows a non-limiting example of a resonant gas sensor 2506Finside view and plan view, including a substrate 2510F, a transducer2522F, a microprocessor 2530F, a ground electrode 2540F, and a sensingmaterial 2550F, in accordance with some implementations. The resonantgas sensor 2506F contains similar elements to those in resonant gassensor 2500F, however, the transducer 2522F in this example is a patchantenna in the shape of a circle, which is electrically coupled to afirst terminal of the microprocessor, rather than a spiral antenna. Theground plane is formed from ground electrode 2540F on the opposite sideof substrate 2510F and is coupled to a second terminal of themicroprocessor through a via in the substrate (not shown in the figure).The substrate 2510F in this example contains the sensing material. Inthis example, the sensing material 2550F (such as a redox mediator) issensitive to an analyte, such that when the resonant gas sensor 2506F isexposed to the analyte, the frequency response of the resonant circuitformed form the transducer 2522F and the sensing material 2550F changes,and the response detected at the microprocessor 2530F changes indicatingthe detection of the analyte. Similar to the examples shown in FIGS.25A, 25C and 25D, the response can either be reflected from the patchantenna transducer 2522F back to the first terminal of themicroprocessor, or be transmitted through the patch antenna transducer2522F and be detected at the second terminal of the microprocessor(connected to the ground electrode 2540F), in different implementations.

The resonant gas sensors described in FIGS. 25A, 25C, 25D and 25F arenon-limiting examples only, and many other variations exist. Forexample, the electrodes, transducers, capacitive elements and/orsubstrates can contain sensing material in any of the above examples. Insuch examples, the sensing material itself can be patterned to affectthe resonant frequencies of the gas sensor circuit. Additional elementscan also be added, for instance, to provide additional sensing materialsthat can affect the response from the circuits in the above examples.The electrodes, transducers, capacitive elements and/or substrates inany of the above examples can contain the particulate carbon describedherein. The electrodes, transducers, capacitive elements and/orsubstrates can be formed in many different shapes as well. For example,the transducers can be rectangular spiral antennas, such as that shownin FIGS. 25A, 25C and 25D, square spiral antennas, ovular spiralantennas, or other types of spiral antennas. The patch antennatransducers can be circular, such as that shown in FIG. 25F,rectangular, square, ovular, or other patch-like shapes. Othertransducer shapes are also possible, such as patterns that are resonantat particular frequency ranges. In some cases, more than one transducercan be driven by a single microprocessor, and multiple signals from thecircuits containing the multiple transducers can also be detected by asingle microprocessor. The circuits can also contain waveguides, such asmicrostrip lines, instead of simple electrical connections, such as thatshown in FIGS. 25A, 25C, 25D and 25F, to conduct the AC signals betweenelements in the gas sensor circuits. The geometry of the waveguides canbe designed such that there is low loss of the AC signals betweenelements in the circuits. The capacitive elements can also be differenttypes than that shown in FIG. 25D. For example, a 3-dimensionalcapacitor can be formed with structured electrodes surrounding a sensingmaterial, to further increase the surface area of the capacitor andfurther improve the capacitance change upon exposure to an analyte. Thecircuits also can be electrically coupled by direct connections, such asthat shown in FIGS. 25A, 25C, 25D and 25F, or can be coupled through adielectric material (since the AC fields can extend outside of awaveguide or other resonant structure).

In some implementations, the transducers used in the gas sensorsdisclosed herein may be examples of the antennas or transducersdescribed in U.S. Pat. No. 10,218,073 entitled “Microwave ChemicalProcessing,” which is incorporated herein by reference.

FIGS. 26A-26C show a time evolution of example spectra produced when ananalyte was detected by a resonant gas sensor similar to that shown inFIG. 25D, but the system in this example used a separate virtual networkanalyser rather than an integrated microprocessor. The resonant gassensor in this example contained a substrate that was paper with asilica layer deposited on the surface, and a printed spiral transducerand capacitive element connected in parallel. The capacitive elementcontained a sensing material with the particulate carbon describedherein and a reactive chemistry additive containing PEUT. The analyte inthis example is isopropyl alcohol mixed with acetone and water. FIGS.26A, 26B and 26C show the reflected signal, such as S11, from thecircuit after about 1-2 seconds, about 15 seconds and about 30 seconds,respectively. In the absence of any analyte the signal is a flat linewith no features at 0 dB. FIG. 26A shows some evidence that an analyteis present after only about 1-2 seconds. Therefore, the design andmaterials of the resonant gas sensor in this example enable a fastdetection of an analyte. FIG. 26C shows multiple peaks representative ofthe analyte detected and illustrates the capability of this type ofresonant gas sensor to identify a species of analyte, such as such bycomparing a detected spectrum with those in a stored library.

The AC signals used by the resonant gas sensors described above containa set of frequencies, such as in a range from 1 MHz to 20 GHz, and themethod by which the signal is applied can vary. For example, a singlefrequency sweep can be performed continuously, or periodically atvarious intervals, such as once every 1 second, 10 seconds, 1 minute, 10minutes, or once an hour. In some cases, different sweeps with differentresolutions, such as frequency spacing between the different frequencieswithin a range can be performed at different intervals.

In one non-limiting example, a first course sweep is performed followedby targeted sweeps. Other similar methods for supplying differentfrequencies to a resonant gas sensor are also possible in differentimplementations. In this example, a first fast/coarse sweep of thefrequency range is performed by the microprocessor, and a peak isdetected. After the first coarse sweep, the microprocessor can drive theresonant sensor to the peak and dither around it to more accuratelyascertain the peak frequency and relative intensity values. Ascertainedpeak values can be compared to a library of analytes, and in some cases,if the library indicates a possible match, the microprocessor can beused to sweep to a second peak in the spectrum of a possible analyte toobtain a second indicator as a check to reduce the number of falsepositives. The peak values, and/or other features of measured spectra,are compared to a library of analytes using an integratedmicroprocessor, such as that shown in FIG. 25A, 25C, 25D or 25F, orcommunicating with a remote processor and/or database. Such a methodcontaining a first course scan followed by targeted subsequent ditherscans can be beneficial to provide high detection accuracy with lowerpower requirements than performing a fine scan over a large set ofpotential analyte resonant frequencies. To further save power, such amethod can be performed periodically, such as once every 1 second, 10seconds, 1 minute, 10 minutes, or once an hour. In some implementations,the system requirements can be relaxed to further save cost and power bytargeting a +/— 20% accuracy level for the concentration of a measuredanalyte. Although such a system may not provide highly accurateconcentrations, it can have low power requirements, such as less than 1nW, or less than 1 pW, and have a low production cost, such as less than1 US dollar per unit, or less than 5 US dollars per unit, depending onthe complexity of the system and the number of analytes capable of beingdetected, and therefore still be useful in many applications whereindication and detection of an analyte are needed and an accurateconcentration measurement is not required, such as to detect thepresence of an explosive inside of a mailed package, or detecting theoccurrence of food spoilage in a packaged food product.

Chemiluminescence Sensors

Other implementations include chemiluminescent sensors as shown in FIG.27 . The sensor 2700 includes a chemiluminescent composite material 2710printed on a substrate 2750. The material 2710 includes a luminescentdye material 2715 tethered to a graphene-based material 2718, where thedye material is chosen based on being a receptor for a certain targetchemical molecule. In some implementations, the graphene-based material2718 is contained within the particulate carbon described herein.Detection of various functional groups of a target chemical is indicatedby a wavelength shift in the absorption spectra of the dye. Due toelectron transfer, there is a change in the structure and excitationenergy of the dye. In other words, due to the presence of electrondonating and withdrawing groups, the electronic state of the dye ischanged, causing the change in color and wavelength. Some non-limitingexample compounds for luminescent dyes include, for example, Ru(Bpy)3,or analogues of it; or Au, Cu or Ag pyrazolytes. For example, peroxidaseor chemical vapors in contact with metallo-organic luminescent materialcan coordinate, resulting in a wavelength shift which can be visuallyobserved. In some cases, the dye-sensitized graphene sheets, such asgraphene oxide, are carboxyl-group functionalized. Due to the highsurface area and beneficial structure of the particulate carbondescribed herein; the composite material provides a structure thatresults in higher sensitivity than conventional chemiluminescentsensors.

Sensor Systems

FIG. 28 shows a non-limiting example implementation of a sensor system2801 in which multiple individual gas sensors are used for detecting oneor more chemical compounds (such as various analytes). Sensor system2801 includes a first sensor 2800 a for detecting a first targetchemical, and a second sensor 2800 b for detecting a second targetchemical. In this implementation, both first sensor 2800 a and secondsensor 2800 b are electrochemical sensors, but other types of sensors,described herein, can also be used. For example, the gas sensors of thesensor system may be electrochemical, high frequency, resonant,chemiluminescent, or a combination of these. In some cases, first sensor2800 a and second sensor 2800 b are printed on the same substrate 2850,such as a label. Each sensor 2800 a/b can include a first electrode 2810a/b, a second electrode 2811 a/b, and an electrolyte 2820 a/b, where thecomponents include particulate carbon and redox mediators as describedin relation to FIG. 21 . Although two sensors 2800 a and 2800 b areshown in this example, more than two sensors can also be included. Insome implementations, an array of sensors can be used to addfunctionality, such as the ability to detect multiple gases, subtract abackground level of moisture and/or improve the sensitivity to ananalyte. Furthermore, other non-printed sensors, such as IR sensors, canbe included. As one example, an IR sensor can be included to detect NO2groups.

An indicator 2860 is coupled to sensors 2800 a and 2800 b throughelectrical circuitry (not shown), where both sensors 2800 a and 2800 bmust positively sense detection of their target chemical in order forthe indicator 2860 to be activated. The combination of all theindividual target substances being present indicates that a certaincompound is present. Types of indicators 2860 that may be used includean optical indicator (such as a light emitting diode), an acousticoutput, or a visual display such as a text or graphic read-out. In otherimplementations, the indicator 2860 may be part of the sensor devices,such as if the individual sensors themselves can provide a positiveindication of detection through a color change of the sensing material,or other indicator mechanism. The sensor system 2801 representsimplementations in which the presence of multiple sensors in one deviceare utilized to detect a combination of chemicals, in order tocharacterize an overall compound. The presence of multiple sensors canalso help rule out false positives.

In the sensor systems for detecting a chemical compound in someimplementations, the sensor systems include a first sensor configured todetect a first target chemical, a second sensor configured to detect asecond target chemical that is different from the first target chemical,and a substrate on which the first sensor and the second sensor areprinted. An indicator indicates when both the first sensor positivelydetects the first target chemical, and the second sensor positivelydetects the second target chemical.

Additionally, other components can be integrated with the gas sensors toadd functionality to a gas sensors system. Some non-limiting examples ofelectro-active labels containing the present gas sensors, that alsocontain a display-based human/machine interface are devices that candisplay telemetry, Q-codes or bar codes, and/or icons. Example scenariosinclude telemetry, where information can be updated, and/or have animage such as a gage; a Q-code (QR code) or bar code, using digital dataor number/text formats; and icons for packages where a color or imagechange is displayed. In these various scenarios, a change in thedisplay, such as in the symbol or color, or a back-and-forth change, canbe used to indicate the condition of the product. These displaytelemetry devices are a new approach to providing information about thecontents of a package status, using a microprocessor-based machine anduser detection of the conditions within a package. The present devicescan also optionally include low power communications components (such asto communicate directly with other electronic devices).

In a non-limiting example, a cardboard shipping box was equipped with anelectrochemical sensor similar to that shown in FIG. 23 , a resonantsensor similar to that shown in FIG. 25D, integrated microprocessors todrive the sensors and detect signals from the sensors, a display tocommunicate visual information (such as a species of analyte detected)and a wireless communication chip (such as a Wi-Fi chip) to communicateinformation to other devices. The electronics were powered by anintegrated battery. The sensing material in the electrochemical sensorand the resonant sensor in this example were both printed, and bothcontained the particulate carbon described herein. The beneficialproperties of the particulate carbon coupled with the sensor designsenabled them to utilize low power (such as with currents from 0.1microamps to 5 microamps) to detect analyte species. This exampleillustrates that gas sensors utilizing the particulate carbon describedherein can be produced using low-cost low power driver/detectionelectronics that can be integrated into a small package. Furthermore,this example showed that such low cost printed gas sensors can also beintegrated with other system components such as displays andcommunication chips.

Printing of Chemical Sensors

In some implementations, gas sensor components (such as electrodes andsensing materials) are printed from carbon-based inks (such ascontaining the particulate carbons describe herein). The electricalcomponents of the present gas sensors can be printed on backingmaterials such as labels and integrated with other hardware componentson a substrate. More than one sensor can be printed on the samesubstrate, such as multiple sensors of the same type, or different typesof sensors (such as electrochemical, high frequency, chemiluminescent).Types of substrates—which also may be referred to as backingmaterials—include rigid or flexible substrates, card stock, labels, orother types of materials used for printing.

In some implementations, printed gas sensor components containing theparticulate carbon described herein are further processed after printingto increase the conductivity of the printed components. For example,particulate carbon containing electrodes, transducers, and/or capacitiveelements of the resonant gas sensors described herein can be furtherprocessed after initial printing to increase the conductivity of theseprinted components. In some implementations, the transducers describedherein require high conductivities (such as greater than 3500 S/m, orgreater than 5000 S/m, or greater than 10000 S/m, in differentimplementations) in order to perform as effective transducers, and insome cases these conductivities cannot be reached using printedparticulate carbon without further processing. Some non-limitingexamples of processes to improve the conductivity of printed particulatecarbon materials are sintering and/or calendaring. For example,sintering can be performed using a plasma, laser or microwave energy. Insome cases, the sintering process can locally heat the printed materialand not affect the substrate and/or other underlying materials. In otherimplementations, calendaring is performed to increase the conductivityof the printed carbon materials. For example, calendaring using a heatedroller, or a roller equipped with an energy source (such as microwaveenergy) to sinter and calendar simultaneously can increase theconductivity of the printed particulate carbon.

In other implementations, high conductivity printed gas sensorcomponents can be formed by printing a mixture of the presentparticulate carbon with other conductive particles added to increase theconductivity of the printed components. For example, the electrodes,transducers, and/or capacitive elements of the resonant gas sensorsdescribed herein can be formed using such mixtures. Some non-limitingexamples of conductive particles that can be mixed with the particulatecarbon described herein are Ag, Sn and/or Sb particles. Printedcomponents for gas sensors containing the particulate carbon andadditional conductive particles can be advantageous in someimplementations because the particulate carbon provides beneficialstructure to the printed components (such as high surface areas), andthe conductive particles improve the conductivity of the printedcomponents.

The devices can be designed to operate in low power ranges, such as 0 to1 volts, or less than 100 μW, or less than 1 μW. In some cases, the lowpower consumption is made possible by the high conductivity, the highsurface area and mesoporous structure of the carbon-based materials usedin printing the components, the small size of the devices, the choice ofdetection methodologies, and optionally the choice of displaytechnologies. The overall device architecture may also use low powertechnology for the various system components (such as gas sensor andindicator).

In some implementations, the printed components are made fromcarbon-based inks and can be electrically coupled to each other and/orto one or more additional hardware components, which can be mounted onthe substrate. The hardware components can be, for example, one or moreof an output display, microcontroller units (MCU), switches, andcapacitors, among others. The hardware components use information storedin, generated by, and/or communicated from the printed components, suchas by processing or displaying data from the printed components. Thepresent devices can also optionally include low power printedcommunications components.

In addition to the particulate carbon described herein, types of carbonmaterials for the various implementations of printed components caninclude, but are not limited to, graphene, graphenes (graphene-basedmaterials), graphene oxide, reduced graphene oxide, graphite oxide,graphite intercalation compounds, graphite, graphene, carbonnano-onions, diamond, p-type diamond, n-type diamond, glassy carbon,amorphous carbon, activated carbon, carbon black and/or carbonnano-tubes, sulfur-based carbons (such as sulfur melt diffused carbon),and carbons with metal (such as nickel-infused carbon, carbon withsilver nanoparticles, graphene with metal). The printed components canbe printed by, for example, screen printing or ink-jet printing.

Reference has been made to implementations of the disclosed invention.Each example has been provided by way of explanation of the presenttechnology, not as a limitation of the present technology. In fact,while the specification has been described in detail with respect tospecific implementations of the invention, it will be appreciated thatthose skilled in the art, upon attaining an understanding of theforegoing, may readily conceive of alterations to, variations of, andequivalents to these implementations. For instance, features illustratedor described as part of one implementation may be used with anotherimplementation to yield a still further implementation. Thus, it isintended that the present subject matter covers all such modificationsand variations within the scope of the appended claims and theirequivalents. These and other modifications and variations to the presentinvention may be practiced by those of ordinary skill in the art,without departing from the scope of the present invention, which is moreparticularly set forth in the appended claims. Furthermore, those ofordinary skill in the art will appreciate that the foregoing descriptionis by way of example only and is not intended to limit the invention.

What is claimed is:
 1. A battery-powered analyte sensing systemcomprising: a printed battery comprising: an anode composed of anon-toxic biocompatible metal; a first carbon-based current collector inelectrical contact with the anode; a three-dimensional hierarchicalmesoporous carbon-based cathode; a second carbon-based currentcollector; and an electrolyte layer disposed between the anode and thecathode, the electrolyte layer configured to activate the printedbattery when the electrolyte is released into one or both the anode andthe cathode; and an analyte sensor comprising: a sensing material; and areactive chemistry additive in the sensing material.
 2. Thebattery-powered analyte sensing system of claim 1, wherein the non-toxicbiocompatible metal includes one or more of Zn, Mg, or Al, and isconfigured to yield a cell voltage between approximately 1.5 volts and 3volts.
 3. The battery-powered analyte sensing system of claim 1, whereinthe battery-powered analyte sensing system is configured to transformthe oxygen into water by exposing the oxygen to ambient air.
 4. Thebattery-powered analyte sensing system of claim 1, wherein theelectrolyte layer is configured to release into one or both the anodeand the cathode in response to one or more of a pressure-activatedrupture of the electrolyte layer or exposure of a hygroscopic compoundto solid salts contained within the anode.
 5. The battery-poweredanalyte sensing system of claim 1, wherein one or both the anode and thecathode comprise a three-dimensional scaffolded mesoporous carbon-basedmaterial.
 6. The battery-powered analyte sensing system of claim 5,wherein the scaffolded mesoporous carbon-based material furthercomprises a plurality of electrically conductive three-dimensionalaggregates formed of graphene sheets.
 7. The battery-powered analytesensing system of claim 6, wherein the three-dimensional aggregates forman open porous scaffold configured to provide electrically conductivepaths between contact points of the graphene sheets.
 8. Thebattery-powered analyte sensing system of claim 1, wherein theelectrolyte layer is configured to be released based on an applicationof pressure to one or both the anode and cathode.
 9. The battery-poweredanalyte sensing system of claim 1, wherein the battery-powered analytesensing system is fabricated by one or more of three-dimensionalprinting or additive manufacturing techniques.
 10. The battery-poweredanalyte sensing system of claim 1, wherein one or both the anode andcathode are three-dimensionally printed onto at least a portion of acontainer comprising one or more of card stock, cardboard, paper, orpolymer-coated paper.
 11. A battery comprising: a first currentcollector including a cathode comprising a first scaffolded mesoporouscarbon-based material; a second current collector including an anodecomprising a second scaffolded mesoporous carbon-based material, thefirst and second current collectors positioned substantially opposite toeach other; and a layer of electrolyte beads disposed between the firstand second current collectors, the electrolyte beads configured toremain in a dormant state until released into one or both the anode andthe cathode based at least in part on pressure applied to theelectrolyte beads.
 12. The battery of claim 11, wherein the electrolytebeads are configured to activate the battery when released into one orboth the anode and the cathode.
 13. The battery of claim 11, wherein thefirst scaffolded mesoporous carbon-based material and the secondscaffolded mesoporous carbon-based material each include a plurality ofelectrically conductive three-dimensional aggregates formed of graphenesheets.
 14. The battery of claim 13, wherein the aggregates are randomlysintered together to form an open porous scaffold configured to provideelectrical conduction between contact points of the graphene sheets. 15.The battery of claim 14, wherein the open porous scaffold includes athree-dimensional hierarchical structure with mesoscale structuring incombination with fractal-like structuring, the fractal-like structuringbased at least in part on a mass, a number of primary particles, amicro, meso, or macro characteristic of a cluster size.
 16. The batteryof claim 15, wherein the first scaffolded mesoporous carbon-basedmaterial and the second scaffolded mesoporous carbon-based material eachcomprise a porous arrangement formed in the open porous scaffold andconfigured to receive the released electrolyte.